SM 7

Service
Workshop Manual
Audi A4 2015 ➤
Audi A4 China 2016 ➤
Audi A5 2016 ➤
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III, B cycle)
Engine ID
CVK DBP CWN CVLA DEM DHD DKU DKU DKY
B A A A A A B A
DLVA DLVB CVK DEM DTA DTA
C B A B
Edition 01.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt D4B80595B99

Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III, B cycle) - Edition 01.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on vehicles with natural gas systems . . . . . . . . . . . . . . 2
2.2 Safety precautions for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.3 Removing and installing poly V-belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3 Installing ball for slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 87
4.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.5 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 92
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 95
4.3 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 95
4.5 Removing and installing stage 3 oil pressure switch F447 . . . . . . . . . . . . . . . . . . . . . . . . 95
4.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 97
4.7 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 97
4.8 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.6 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.7 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 122
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 123
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 124
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3 Removing and installing coolant pipes for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1 Exploded view - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.4 Removing and installing radiator blind control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
ii Contents
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5 Gas injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.1 Exploded view - gas rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.2 Removing and installing gas rail with gas injection valve N366 / N367 / N368 / N369 . . . . 190
5.3 Removing and installing gas injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6 Gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6.1 Exploded view - gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6.2 Removing and installing gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7.4 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.5 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 201
7.6 Removing and installing gas rail temperature and pressure sensor GX21 . . . . . . . . . . . . 202
7.7 Removing and installing sensor module GX23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10.1 Exploded view - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10.2 Removing and installing engine/motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . 211
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.4 Removing and installing front silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.5 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1.6 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.7 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Contents iii
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
iv Contents
00 – Technical data
1 Identification
(ARL006806; Edition 01.2020)
All information can be found in ⇒ Servicing 4-cylinder engine, 2.0
ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on vehicles with natural
gas systems”, page 2
⇒ “2.2 Safety precautions for all vehicles”, page 2
2.1 Safety precautions when working on vehicles with natural gas systems
Risk of explosion due to uncontrolled gas escape in connection
with ignition sources and electrostatic discharge - risk of death!
Danger of severe or fatal injuries due to explosion.
– Never drive a vehicle with a natural gas system into the work‐
shop if you can clearly hear gas escaping. Instead, park the
vehicle outside and set up a protected area ⇒ Natural gas
engines - General information; Rep. gr. 20 ; Fuel tanks; Set‐
ting up and marking a protected area .
– Work on natural gas systems may only be performed by spe‐
cially trained persons ⇒ Natural gas engines - General infor‐
mation; Rep. gr. 00 ; Safety briefing/employee qualification .
– Gas tank must be closed manually on vehicles with natural gas
systems if gas can be heard escaping and smelt ⇒ Fuel supply
system - g-tron; Rep. gr. 20 ; Fuel tanks; Closing fuel tank
shut-off valves mechanically .
Risk of explosion due to flammable natural gas - risk of death!

Risk of explosion due to static discharge near natural gas systems
- risk of death! Escaping natural gas may ignite and cause an
explosion. Danger of severe or fatal injuries due to explosion.
– Wear protective clothing consisting of at least 35% cotton.
– Wear protective gloves consisting of at least 35% cotton.
– Wear safety shoes with ESD protection.
Risk of injury due to high pressure

Uncontrolled gas escape may occur under high pressure. Danger
of frostbite to hands and other parts of the body.
– Dissipate high pressure in natural gas system before perform‐
ing work on natural gas system ⇒ Fuel supply system - g-tron;
Rep. gr. 20 ; Fuel tanks; Dissipating pressure in natural gas
high-pressure pipe .
– Check for leaks after performing work on the natural gas sys‐
tem.
2.2 Safety precautions for all vehicles

ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .
2 Rep. gr.00 - Technical data

3 Repair instructions
ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .
3. Repair instructions 3
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 4
⇒ “1.2 Securing engine to engine and gearbox support”,
page 54
⇒ “1.3 Installing engine”, page 54
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles without particulate filter”,
page 4
⇒ “1.1.2 Removing engine - vehicles with particulate filter”,
page 20
⇒ “1.1.3 Removing engine - vehicles with natural gas system”,
page 38
1.1.1 Removing engine - vehicles without par‐

ticulate filter
Special tools and workshop equipment required
♦ Support bracket - 10-222A-
♦ Lifting tackle - 2024A-
4 Rep. gr.10 - Removing and installing engine

♦ Gearbox support - 3147-
♦ Lambda probe open ring spanner set - 3337-
♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Workshop hoist - VAS 6100-
1. Removing and installing engine 5

♦ Engine bung set - VAS 6122-
♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
♦ Adapter - VAS 6948-

♦ Locking pin - T10060A-
♦ -T40093/6- from engine support supplementary set - T40093-
♦ Ratchet wrench (21 mm) - T40263-
♦ Adapter - T40314-
♦ Protective gloves
♦ Safety goggles

Procedure
Note
♦ The engine is removed upwards without gearbox.

♦ Re-install all cable ties in original positions.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– On vehicle versions with manual gearbox: Select 4th gear.
– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
WARNING
The cooling system is under pressure when the power unit is

hot. Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Release fastener -arrow- and open filler cap -1- on coolant

expansion tank.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove noise insulation panels ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Remove wheel spoiler (left and right) as well as wheel housing
liner (front right) ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(front) .

– On relevant equipment version: Unplug electrical connector

-2- for variable intake manifold changeover valve - N335- and
pull water drain -1- off downwards -arrow-.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
Vehicles with starter-alternator:
Remove air intake grille (left and right) and closure plate at bump‐
er cover ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper
(front); Exploded view - bumper cover .
All vehicles (continued):

– Remove bolts -arrows- and detach air duct -2-.
– Unplug electrical connector -2- for air mass meter - G70- .

– Disconnect vacuum hose -3-.
– Release hose clip -4- and disconnect air hose.
– Lift off air cleaner housing -1-.
– Seal off turbocharger connection with sealing plug (thoroughly
cleaned) from engine bung set - VAS 6122- .
– Release catch -arrow B- and open electronics box -1-

-arrow A-.
– Remove nut -2- and move B+ wire clear.
– Move wiring duct (top) clear.

– Remove nuts -1- (accessible from above) for front silencer.
Note
The nut -2- and bolt -3- are removed at a later stage.
– Unplug electrical connector -1- for charge pressure sender -

G31- .
– Loosen screw-type clip -2- and detach air pipe from throttle
valve module - GX3- .
– Place collector tank from coolant collecting system -VAS

5014- or drip tray for workshop hoist - VAS 6208- underneath.
– Lift retaining clip -2-, disconnect coolant hose from radiator
(bottom right) and drain off coolant.
– Unfasten front section of wheel housing liner (front left) and
press slightly towards rear ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Release hose clip -1-, disconnect air hose and detach it down‐
wards.

Vehicles without belt-driven starter-alternator:
Caution
Running a used poly V-belt in the opposite direction could

cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– To slacken poly V-belt turn tensioner in direction of -arrow-.

– Lock tensioner with locking pin - T10060A- .
– Take off poly V-belt.
Vehicles with belt-driven starter-alternator:
Caution


– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
taching and attaching air conditioner compressor at bracket .
– Unscrew bolt -arrow-, detach wiring duct -1- from sump (top
section) towards front and press it downwards.

– Release hose clip -arrow- and detach air hose (right-side) from
turbocharger.
– Detach electrical connector -2- from bracket and unplug.

– Release fasteners -arrows- and move wiring duct -1- clear.
– Move clear electrical wiring harness leading to engine.
– Remove nut -arrow- and move earth wire clear.
– If fitted, remove bolt -1- for support mounting on both sides.

Vehicles with belt-driven starter-alternator:

– Release catches -arrow- and detach air ducts -1, 3-.
– Unclip air duct -2-.
– Detach air duct (top) -arrow-.
– Remove bolt -2- on both sides and press radiator bracket -1-
with radiator towards front -arrow-.
– Release fasteners -arrows- on both sides and pull retaining

pins -1- for radiator out upwards.
– Push radiator slightly forwards.


– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Unbolt drive shaft (left and right) from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Remove nut -2- and bolt -3- for front silencer.
Note
-Item 1- is already removed.
Caution
Risk of damage to flexible joints in front silencer.

♦ Do NOT bend the flexible joints in the front silencer more
than 10°.
– Remove bolts -arrows-.
– Loosen clamp -arrows- and push towards rear.

– Detach front silencer.

– Remove nut -2- for catalytic converter.
Note
The nuts -1- are removed at a later stage.
– Detach bottom cover -1- from gearbox -arrow-.
– Counterhold crankshaft using ratchet wrench, 21 mm -

T40263- and adapter -T40314- when slackening bolts for
flywheel.
Caution
Irreparable engine damage can be caused if the camshaft tim‐

ing chain slips.
♦ Only turn crankshaft in direction of engine rotation.
– Then turn crankshaft in steps of 120° in direction of engine

rotation -arrow-.
– Remove 3 bolts -arrow- for flywheel -1-.

Vehicles with manual gearbox:

– Unscrew bolt -1- using ring spanner insert, 16 mm - V.A.G
1332/14- and adapter - VAS 6948- .
– Remove bolts -6 ... 10- securing gearbox to engine.
Vehicles with dual clutch gearbox:

1332/14- and adapter - VAS 6948- .

– Remove bolt -2- for engine mounting on both sides.
– Unplug electrical connector -1- for Lambda probe 1 after cat‐

alytic converter - GX7- -item 2- and move wiring clear. (Instal‐
lation position varies.)

– Unplug electrical connector -1- for Lambda probe 1 before

catalytic converter - GX10- -item 2-. (Installation position var‐
ies.)
– Unscrew Lambda probe 1 before catalytic converter - GX10-
-item 2- using a tool from Lambda probe open ring spanner
set - 3337- .
– Unscrew nuts -1- and detach catalytic converter upwards.
– Disconnect fuel hose -1- ⇒ Fuel supply system; Rep. gr. 20 ;

Plug-in connectors; Disconnecting plug-in connectors .
– Release hose clip -2- and disconnect hose for activated char‐
coal filter system. (Different versions.)
– Lift retaining clip -arrow- and disconnect coolant hose.

– Lift retaining clips -arrows-, disconnect coolant hoses and

move them clear.
– Unplug electrical connector -1- for coolant shortage indicator
switch - F66- .
– Unscrew bolt -2- and detach coolant expansion tank -3-.
– Lift retaining clips -1, 3- and disconnect coolant hoses.

– Lift retaining clip -2- and disconnect coolant hose.
– Release hose clip -arrow- on coolant pipe (left-side) and de‐

tach coolant hose.



– Unplug electrical connector -1- at engine control unit.
– Move electrical wiring harness clear and place on engine.
– Release catch -arrow- and disconnect vacuum hose -1-.

– Remove bolts -2 ... 5- (accessible from above) securing engine
to gearbox.
– Separate starter slightly from gearbox and leave in position.

to gearbox.


– Set up support bracket - 10-222A- with adapters -10-222A/22-
on bolted flanges of wing panels (left and right) as illustrated.
– Use gearbox support - 10-222A/11- to hook spindle - 3147-
onto gearbox.
– Take up weight of gearbox with spindle.
Note
Shown in illustration with engine removed.
– Attach lifting tackle - 2024A- to engine and workshop hoist -

VAS 6100- as shown in illustration.
WARNING
Risk of accident.
♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.
– Raise engine until engine mountings are clear.

– Tighten spindle - 10-222A/11- further.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide engine out of engine compartment when
lifting out.
– Separate engine from gearbox and lift engine out of engine

compartment.
1.1.2 Removing engine - vehicles with partic‐

ulate filter





♦ Safety goggles
Procedure
Note


WARNING



expansion tank.
noise insulation .
(front) .
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
– Remove lock carrier cover, air intake grille (left and right) and
closure plate at bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .
– Remove bolts -arrows- and detach air ducts -1, 2-.


-arrow A-.

Caution



G31- .
– Loosen screw-type clip -2- and detach air pipe from throttle
valve module - GX3- .
– Unfasten front section of wheel housing liner (front left) and
press slightly towards rear ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
wards.


– Remove bolts -arrows- and press wiring duct -1- downwards.

turbocharger.


– Remove bolt -1- on both sides.



– Push radiator slightly forwards.
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .
– Unscrew nuts -arrows- for front silencer.
Caution

than 10°.
– Unscrew bolts -arrows- (shown on right side).


– Remove bolt -arrow- on bracket for particulate filter.
– Remove bolt -arrow- on bracket for catalytic converter.
Note


flywheel.
Caution

ing chain slips.

rotation -arrow-.

1332/14- and adapter - VAS 6948- .


1332/14- and adapter - VAS 6948- .

– Unplug electrical connector -1- for exhaust gas temperature

sender 3 - G495- and move wiring clear.
– Remove nuts -arrows- and press particulate filter -1- to rear.

Pressure differential sender for particulate filter - G1037- - version

1:
– Unplug electrical connector -1- for pressure differential sender
for particulate filter - G1037- .
– Unclip bracket with pressure differential sender from intake
manifold -arrow- and move clear.
– Unplug electrical connector -1- for vacuum sender - G608-

-item 2-.

2:
– Unplug electrical connector -3-.
– Remove bolt -1- and move pressure differential sender for
particulate filter - G1037- clear.
– Move electrical wiring clear at heat shield -1-.

– Remove nuts -arrows- and bolt -2- and detach heat shield
(shown with particulate filter removed).

– Release retaining clip -3- and move vacuum hose clear.

– Remove bolt -1- and push bracket to one side. (Different ver‐
sions.)
All versions (continued):
– Take electrical connector -2- for exhaust gas temperature
sender 3 - G495- out of bracket and unplug.
– Detach particulate filter.

alytic converter - GX7- -item 1- and move wiring clear.

catalytic converter - GX10- -item 2-.
– Move electrical wiring harness clear at engine and tie up to left
side.

– Unscrew nuts -1- and detach catalytic converter upwards to‐

wards rear.
– Disconnect fuel hose -1- ⇒ Fuel supply system; Rep. gr. 20 ;

Plug-in connectors; Disconnecting plug-in connectors .
coal filter system.
– Lift retaining clip -arrow- and disconnect coolant hose.

move them clear.
switch - F66- .



tach coolant hose.


– Unplug electrical connector -1- at engine control unit.

– Unplug electrical connector -arrow- for starter-alternator.

to gearbox.

to gearbox.


onto gearbox.
Note

WARNING
Risk of accident.

Caution

lifting out.

compartment.
1.1.3 Removing engine - vehicles with natural

gas system





♦ Safety goggles
Procedure
Note

– Observe safety precautions ⇒ Servicing 4-cylinder engine, 2.0

– Observe safety precautions when working on the natural gas
system ⇒ page 2 .
– Observe rules for cleanliness ⇒ Servicing 4-cylinder engine,
2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for
cleanliness .
WARNING
Risk of explosion due to escaping natural gas - risk of death!

Uncontrolled escape of natural gas may occur if the manual
fuel tank shut-off valve is defective. In addition, third parties
may activate the natural gas system unintentionally.
♦ Pressure in natural gas high-pressure pipe must be dissi‐
pated by a specially instructed person.
♦ Shut off natural gas fuel tanks electrically and manually.

– Dissipate pressure in natural gas high-pressure pipe ⇒ Fuel

supply system - g-tron; Rep. gr. 20 ; Fuel tanks; Dissipating
fuel pressure in high-pressure section .
– Switch off ignition and remove ignition key.
– Detach electrical connectors -2- from bracket and unplug.
– Release catches -arrows- and detach engine control unit -
J623- -item 3-.
– Unplug electrical connectors -1-.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Release catches -arrows B- and open cover -1- -arrow A-.
WARNING


expansion tank.
noise insulation .
(front) .


– Unplug electrical connector -2- for air mass meter - G70- and
move connector clear.

-arrow A-.
Note
The nut -2- and bolt -3- are removed at a later stage.

– Release hose clip -arrow- and detach air hose downwards

from throttle valve module - GX3- .

– Release hose clip -2- and detach from coolant pipe -1-.
– Unscrew bolt -3- on both sides and tie up coolant pipe to side.

G31- .
wards.

Note
♦ Running a used poly V-belt in the opposite direction could

♦ Before removing the poly V-belt, mark the direction of rotation
with chalk or a felt-tip pen for re-installation.

– Remove bolt -1- for support mounting -2- (both sides).
– Unscrew bolt -arrow-, detach wiring duct -1- from sump (top
section) towards front and press it downwards.

turbocharger.


– Remove heat shield for drive shaft (right-side) ⇒ Running
installing heat shield for drive shaft .

Caution
Avoid damage to flexible joints.

♦ Do not bend flexible joints more than 10°.
– Loosen clamp -arrow-.

– Detach front exhaust pipe from front silencer and remove.
Note


flywheel.
Caution

ing chain slips.

rotation -arrow-.

1332/14- and adapter - VAS 6948- .

1332/14- and adapter - VAS 6948- .




catalytic converter - GX10- -item 2-. (Installation position var‐
ies.)
– Unscrew Lambda probe 1 before catalytic converter - GX10-
-item 2- using a tool from Lambda probe open ring spanner
set - 3337- .

– Unscrew nuts -1- and detach catalytic converter upwards.
WARNING
The fuel system is pressurised.

Risk of injury as fuel may spray out.
• Release pressure (wrap a clean cloth around connection
and open connection carefully).
– Release hose clip -1- and detach fuel hose.

coal filter system.

– Release hose clip -1- on rear coolant pipe and detach coolant
hose.

– Move coolant hose -3- clear and move it to right side.



tach coolant hose.


– Unscrew natural gas low-pressure pipe -1- from gas rail; to do
so, counterhold at connection with a suitable tool.
– Seal off open lines and connections with plugs (thoroughly
– Release hose clip -2- on rear coolant pipe and detach coolant
hose.


to gearbox.

to gearbox.

onto gearbox.
Note


WARNING
Risk of accident.

Caution

lifting out.

compartment.
1.2 Securing engine to engine and gearbox

support
All procedures are described in ⇒ Servicing 4-cylinder engine,
2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Removing and installing engine;
Securing engine to engine and gearbox support .
1.3 Installing engine

♦ All special tools specified in removal procedure
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65

♦ ⇒ “2.1 Exploded view - assembly mountings”, page 59

♦ Bolts securing engine to gearbox ⇒ Gearbox; Rep. gr. 34 ;
Removing and installing gearbox; Tightening torques for gear‐
box
Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings after removal.
♦ On vehicles with manual gearbox, a needle bearing must be
fitted in the drive plate ⇒ Servicing 4-cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr. 13 ; Cylinder block (gearbox end); Re‐
newing needle bearing in drive plate .
♦ Hose connections and hoses for charge air system must be
free of oil and grease prior to fitting.
♦ Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ If you intend to secure the charge air hoses at their connec‐
tions with used hose clips, spray rust remover onto the worm
threads before installing.
– Attach engine to gearbox, but do not yet tighten gearbox/en‐

gine connecting bolts ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Installing gearbox .
– Slacken spindle - 10-222A/11- .
– Lower workshop hoist and place engine/gearbox assembly
onto engine mountings.

– Tighten bolts -2- (left and right) for engine mounting.

– Detach workshop hoist - VAS 6100- and lifting tackle - 2024A- .
– Tighten gearbox/engine connecting bolts ⇒ Gearbox; Rep. gr.
34 ; Removing and installing gearbox; Tightening torques for
gearbox .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Connect fuel hose ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
– Vehicles with natural gas system: Secure natural gas low-
pressure pipe to gas rail ⇒ page 189 (counterhold at connec‐
tion with a suitable tool).
– Install Lambda probe 1 before catalytic converter - GX10- ⇒
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ;
Lambda probe; Removing and installing Lambda probe .
– If removed previously, install intermediate steering shaft ⇒
Running gear, axles, steering; Rep. gr. 48 ; Steering column;
Removing and installing intermediate steering shaft .
– Secure drive shaft with bolts ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
– If unfastened previously, bolt on radiator ⇒ page 140 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end); Remov‐
ing and installing poly V-belt tensioner .
– If removed previously, install plenum chamber partition panel
⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel .
– Install air cleaner housing ⇒ page 178 .
– Install lock carrier cover, air intake grille (left and right) and
cover .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install catalytic converter ⇒ Servicing 4-cylinder engine, 2.0
ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control system; Re‐
moving and installing catalytic converter .
– Align the exhaust system so it is free of stress ⇒ page 228 .
– Fill up with engine oil (⇒ Maintenance ; Booklet 830 ; Main‐
tenance; Engine oil: filling up ), and check oil level (⇒ Mainte‐
nance ; Booklet 830 ; Maintenance; Engine oil: checking oil
level and correcting if necessary ).
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .

Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– If engine was renewed, perform adaptions listed in Guided

Function “01 - Functions, engine mechanics” ⇒ Vehicle diag‐
nostic tester.
Caution
Risk of damage to components.

♦ Only perform additional adaptions for those components
which were renewed after removal.
– Connect coolant hose with plug-in connector ⇒ page 142 .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 102 .

– Install engine cover panel ⇒ Servicing 4-cylinder engine, 2.0
ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel; Removing
and installing engine cover panel .
– Install wheel housing liners and wheel spoiler ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

Vehicles with natural gas system:
WARNING

♦ Natural gas system must be re-started by a specially in‐
structed person.
– Open manual shut-off mechanisms of mechanical tank shut-

off valves using extension -T40333- and hand wheel -
T50026- , and plug in electrical connectors if necessary.
WARNING

Leaks in the natural gas system can cause uncontrolled es‐
cape of natural gas.
♦ Check natural gas system for leaks.
– Perform leak test on low-pressure section of natural gas sys‐

tem ⇒ Natural gas engines - General information; Rep. gr.
00 ; Checking natural gas system .

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 59
⇒ “2.2 Supporting engine in installation position”, page 62
⇒ “2.3 Removing and installing engine mountings”, page 63
⇒ “2.4 Removing and installing gearbox mounting”, page 68
2.1 Exploded view - assembly mountings

♦ Exploded view - engine mounting ⇒ page 59
♦ Exploded view - gearbox mounting for manual gearbox
⇒ page 60
♦ Exploded view - gearbox mounting for dual clutch gearbox
⇒ page 61
Exploded view - engine mounting
1 - Subframe
2 - Bolt
❑ For vehicles with sup‐
port mounting
❑ 20 Nm
3 - Bolt
❑ For vehicles with sup‐
port mounting
❑ 10 Nm
4 - Support mounting
❑ Depending on equip‐
ment version; for correct
type refer to ⇒ Electron‐
ic parts catalogue
❑ Removing and installing
⇒ page 67
❑ Installation position
⇒ page 60
5 - Bolt
❑ 55 Nm
6 - Engine support
❑ Different versions avail‐
able; for allocation refer
to ⇒ Electronic parts
catalogue
⇒ page 71
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
10 - Engine mounting
❑ Equipment version with:
♦ Left electrohydraulic engine mounting solenoid valve - N144-
2. Assembly mountings 59
♦ Right electrohydraulic engine mounting solenoid valve - N145-

❑ Solenoid valve integrated in engine mounting; cannot be renewed separately if defective
❑ Removing and installing ⇒ page 63
11 - Bolt
❑ Renew after removing
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm
Installation position of support mounting

♦ Projection -2- on engine support must engage in recess -1- on
support mounting.
Exploded view - gearbox mounting for manual gearbox

1 - Nut
❑ Only remove if detach‐
ing gearbox mounting
from gearbox support
❑ Tightening torques ⇒ 6-
speed manual gearbox;
Rep. gr. 34 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
2 - Bolt
mountings; Exploded
ings
3 - Tunnel cross member
⇒ 6-speed manual
gearbox; Rep. gr. 34 ;
Assembly mountings;
Exploded view - assem‐
bly mountings
4 - Stop plate
❑ For gearbox mounting
5 - Gearbox mounting
⇒ page 68
6 - Bolt
mountings; Exploded
ings
7 - Final drive
8 - Nut
❑ Only remove if detaching gearbox mounting from gearbox support
❑ Tightening torques ⇒ 6-speed manual gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view -
assembly mountings
9 - Gearbox support
❑ Removing and installing ⇒ “2.4 Removing and installing gearbox mounting”, page 68
10 - Bolt
❑ Tightening torques ⇒ 6-speed manual gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view -
assembly mountings
11 - Bolt
❑ 9 Nm
12 - Bracket
❑ For electrical connector
Exploded view - gearbox mounting for dual clutch gearbox
1 - Bolt
speed dual clutch gear‐
box; Rep. gr. 34 ; As‐
sembly mountings; Ex‐
ploded view - assembly
mountings
2 - Tunnel cross member
⇒ 7-speed dual clutch
gearbox; Rep. gr. 34 ;
Assembly mountings;
Exploded view - assem‐
bly mountings
3 - Stop plate
❑ For gearbox mounting
4 - Gearbox mounting
⇒ page 68
5 - Final drive
6 - Nut
❑ Only remove if detach‐
ing gearbox mounting
from gearbox support
speed dual clutch gear‐
box; Rep. gr. 34 ; As‐
sembly mountings; Ex‐
ploded view - assembly
mountings
7 - Gearbox support
⇒ “2.4 Removing and in‐
stalling gearbox mount‐
ing”, page 68
8 - Bolt
❑ Tightening torques ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view
- assembly mountings
9 - Bolt
10 - Nut
2.2 Supporting engine in installation posi‐

tion

Procedure
– Remove engine cover panel ⇒ Servicing 4-cylinder engine,
2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel; Re‐
moving and installing engine cover panel .
– Set up support bracket - 10-222A- on upper wheel housing
longitudinal members (left and right), as shown.
– Attach spindles -10-222A/11- to engine lifting eyes.
– Take up weight of engine with spindles, but do not lift.
Assembling
Assembly is carried out in reverse sequence; note the following.
2.3 Removing and installing engine mount‐

ings
⇒ “2.3.1 Removing and installing engine mountings - vehicles
without natural gas system”, page 63
⇒ “2.3.2 Removing and installing engine mountings - vehicles with
natural gas system”, page 65
⇒ “2.3.3 Removing and installing support mounting”, page 67
2.3.1 Removing and installing engine mount‐

ings - vehicles without natural gas sys‐
tem
Removing
– Remove noise insulation (front) ⇒ General body repairs, ex‐
noise insulation .
– Remove wheel spoiler (front) ⇒ General body repairs, exteri‐
or; Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
– Unplug electrical connector -2- for electrohydraulic engine

mounting solenoid valve.
Engine mounting (left-side):
– If fitted, unscrew bolt -1- for support mounting.
Engine mounting (right-side):

– If fitted, remove support mounting (right-side) ⇒ page 67 .
– Release hose clip -arrow- and detach air hose.
– Remove bolt -arrow- and move bracket -1- clear with electrical
wiring harness.

Both sides (continued):
Caution
Risk of damage to drive shafts.

♦ When lifting the engine, the drive shafts must not make
contact with the suspension struts.
– Support engine in installation position ⇒ page 62 and take up

weight with spindles -10-222A/11- until load on engine mount‐
ing is relieved.
– Remove bolts -arrows- and detach engine mounting -1-.
Installing
Installation is carried out in reverse order; note the following:
Note
After removing, renew bolts tightened with specified tightening

angle.

Tightening torques
♦ ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr.
21 ; Charge air system; Exploded view - hose connections for
charge air system
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
2.3.2 Removing and installing engine mount‐

ings - vehicles with natural gas system
Removing
noise insulation .
– Remove wheel spoiler (front) ⇒ General body repairs, exteri‐
or; Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
– Release hose clip -arrow- and detach air hose downwards
from throttle valve module - GX3- .

G31- .
wards.
– Unplug electrical connector -2- for electrohydraulic engine

mounting solenoid valve.
Engine mounting (left-side):
– Remove bolt -1- for support mounting.
Engine mounting (right-side):

– Remove support mounting (right-side) ⇒ page 67 .
– Release hose clip -arrow- and detach air hose.

– Remove bolt -arrow- and move bracket -1- clear with electrical
wiring harness.
Both sides (continued):
Caution

– Support engine in installation position ⇒ page 62 and take up

weight with spindles -10-222A/11- until load on engine mount‐
ing is relieved.
– Remove bolts -arrows- and detach engine mounting -1-.

Installing
Note

angle.
– Install support mountings ⇒ page 67 .

Tightening torques
charge air system
2.3.3 Removing and installing support mount‐

ing
Removing
noise insulation .
– Unscrew bolts -1, 3- and detach support mounting -2-.

Installing
Note

angle.
– Observe correct installation position ⇒ page 60 .

Tightening torques
2.4 Removing and installing gearbox

mounting
Removing gearbox support with gearbox mounting
– Remove tunnel cross member ⇒ Gearbox; Rep. gr. 34 ; As‐
sembly mountings; Exploded view - assembly mountings .
– Remove bolts -arrows- and detach gearbox support and gear‐
box mounting from gearbox.
Removing gearbox mounting

– Unscrew bolts -1- and detach stop -2- for gearbox mounting.
– Remove nut -5- and detach gearbox mounting -3- from gear‐
box support -4-.
Installing
– Tighten nut -5- hand-tight initially.
– Tighten bolts -1- and then nut -5-.
The remaining installation steps are carried out in the reverse se‐
quence.
Tightening torques
♦ ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view

3 Engine cover panel

All procedures can be found in ⇒ Servicing 4-cylinder engine, 2.0
ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .
3. Engine cover panel 69

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 70
⇒ “1.2 Removing and installing poly V-belt”, page 70
⇒ “1.3 Removing and installing poly V-belt tensioner”, page 70
⇒ “1.4 Removing and installing vibration damper”, page 70
⇒ “1.5 Removing and installing bracket for ancillaries”,
page 70
⇒ “1.6 Removing and installing engine support”, page 71
1.1 Exploded view - cylinder block (pulley

end)
All components are described in ⇒ Servicing 4-cylinder engine,
2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end);
Exploded view - cylinder block (pulley end) .
1.2 Removing and installing poly V-belt

Removing and installing poly V-belt .
1.3 Removing and installing poly V-belt ten‐

sioner
Removing and installing poly V-belt tensioner .
1.4 Removing and installing vibration damp‐

er
Removing
– Remove radiator cowl ⇒ page 151 .
– Vehicles with natural gas system: Unscrew bolt -3- on both
sides and press coolant pipe towards rear.
All further procedures are described in ⇒ Servicing 4-cylinder
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing vibration damper .
Installing
Additional work:
– Install radiator cowl ⇒ page 151 .
Tightening torques
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 127
1.5 Removing and installing bracket for an‐

cillaries
Removing and installing bracket for ancillaries .
70 Rep. gr.13 - Crankshaft group

1.6 Removing and installing engine support

⇒ “1.6.1 Removing and installing engine support (left-side) - ve‐
hicles without natural gas system”, page 71
⇒ “1.6.2 Removing and installing engine support (left-side) - ve‐
hicles with natural gas system”, page 72
⇒ “1.6.3 Removing and installing engine support (right-side)”,
page 73
1.6.1 Removing and installing engine support

(left-side) - vehicles without natural gas
system
Removing
– Lift retaining clip -3-, disconnect coolant hose and move it
clear.
switch - F66- .
– Remove bolt -4- and push coolant expansion tank -2- to one
side.
– Remove top bolts -2- for engine support -1-.
Note
♦ Shown in illustration with engine removed.

♦ Bolts -3- are removed at a later stage.
– If fitted, remove support mounting (left-side) ⇒ page 67 .

– Remove engine mounting (left-side) ⇒ page 63 .
– Unplug electrical connector -arrow- at air conditioner com‐

pressor.
1. Cylinder block (pulley end) 71

– Unscrew bottom bolts -3- and detach engine support (left-side)

-1-.
Note
Installing
Note

angle.

– Install engine mountings ⇒ page 63 .
– If removed previously, install support mounting ⇒ page 67 .
Tightening torques

(left-side) - vehicles with natural gas
system
Removing
– Remove support mounting (left-side) ⇒ page 67 .
– Remove engine mounting (left-side) ⇒ page 65 .
– Remove poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
ing and installing poly V-belt .

– Unscrew bolts -2, 3- and detach engine support (left-side)

-1-. (Engine has been removed in illustration).
Installing
Note

angle.
– Install air conditioner compressor ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
ing and installing poly V-belt .
– Install support mountings ⇒ page 67 .
Tightening torques

(right-side)
Removing
– Remove engine mounting (right-side) ⇒ page 63 .
– Remove nut -2- and move bracket with electrical wiring clear.
– Remove bolts -arrows- and detach engine support -1- (right-
side).
Note
Installing
Note

angle.

ing battery .
Tightening torques
1. Cylinder block (pulley end) 73

2 Cylinder block (gearbox end)

All procedures and components can be found in ⇒ Servicing 4-
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block
(gearbox end) .

3 Crankshaft
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Crankshaft .
3. Crankshaft 75
4 Balance shaft
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance shaft .

5 Pistons and conrods

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons and
conrods .
5. Pistons and conrods 77

15 – Cylinder head, valve gear

1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 78
⇒ “1.2 Removing and installing timing chain cover”, page 78
1.1 Exploded view - timing chain cover

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover; Exploded
view - timing chain cover .
1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain cover (top)”,
page 78
⇒ “1.2.2 Renewing timing chain cover (bottom)”, page 78
1.2.1 Removing and installing timing chain

cover (top)
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover;
Removing and installing timing chain cover .
Installing
Additional work:
– Install lock carrier cover ⇒ General body repairs, exterior;
Tightening torques
♦ ⇒ “2.1 Exploded view - air cleaner housing”, page 177
1.2.2 Renewing timing chain cover (bottom)

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover; Removing
and installing timing chain cover .
78 Rep. gr.15 - Cylinder head, valve gear

2 Chain drive
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive .
2. Chain drive 79
3 Cylinder head
⇒ “3.1 Exploded view - cylinder head”, page 80
⇒ “3.2 Removing and installing cylinder head”, page 80
⇒ “3.3 Checking compression”, page 85
3.1 Exploded view - cylinder head

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Exploded view
- cylinder head .
3.2 Removing and installing cylinder head

⇒ “3.2.1 Removing and installing cylinder head - vehicles without
particulate filter”, page 80
⇒ “3.2.2 Removing and installing cylinder head - vehicles with
⇒ “3.2.3 Removing and installing cylinder head - vehicles with
3.2.1 Removing and installing cylinder head -

vehicles without particulate filter
Removing
– Unscrew bolts -arrows- for front silencer.
– Loosen bolted connections -arrows- and push clamp towards

rear.

Caution

– Lower front silencer -2- slightly and secure it with a cable tie
-1-, as shown.
– Unplug electrical connectors and move wiring clear:

1 - For oil pressure switch - F22- -item 2-
3 - For oil pressure switch for reduced oil pressure - F378-
-item 4-
5 - For piston cooling jet control valve - N522- -item 7-
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Re‐
moving and installing cylinder head .
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 213

vehicles with particulate filter
Removing
– Remove front silencer ⇒ page 223 .
– Remove bolt -arrow- on bracket for particulate filter.
3. Cylinder head 81
– Remove bolt -arrow- on bracket for catalytic converter.

1:
– Move bracket with pressure differential sender clear at intake
manifold -arrow-.
Installing
Additional work:
– Install front silencers ⇒ page 223 .
Tightening torques
26 ; Emission control system; Exploded view - emission con‐
trol system

vehicles with natural gas system
Removing


system ⇒ page 2 .
cleanliness .
WARNING


– Unbolt coolant pipes (rear) and press towards rear
⇒ page 135 .
3. Cylinder head 83
– Loosen clamp -arrow- and detach front exhaust pipe from front
silencer.
Caution

– Lower front exhaust pipe -2- slightly and secure it with a cable
tie -1-, as shown.
– Unplug electrical connectors and move wiring clear:

1 - For oil pressure switch - F22- -item 2-
3 - For oil pressure switch for reduced oil pressure - F378-
-item 4-
5 - For piston cooling jet control valve - N522- -item 7-
Installing
Additional work:
– Install rear coolant pipes ⇒ page 135 .
– Secure natural gas low-pressure pipe to gas rail
⇒ page 189 ; to do so, counterhold at connection with a suit‐
able tool.

WARNING

structed person.

WARNING


Tightening torques
3.3 Checking compression

ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking com‐
pression .
3. Cylinder head 85
4 Valve gear
⇒ “4.1 Exploded view - valve gear”, page 86
⇒ “4.2 Removing and installing camshaft”, page 86
⇒ “4.3 Installing ball for slider”, page 87
⇒ “4.4 Removing and installing actuators for camshaft adjust‐
ment”, page 87
⇒ “4.5 Removing and installing camshaft control valve 1 N205 ”,
page 87
⇒ “4.6 Removing and installing valve stem oil seals”, page 88
4.1 Exploded view - valve gear

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded view -
valve gear .
4.2 Removing and installing camshaft

⇒ “4.2.1 Removing and installing camshaft - vehicles without par‐
ticulate filter”, page 86
⇒ “4.2.2 Removing and installing camshaft - vehicles with partic‐
ulate filter”, page 86
4.2.1 Removing and installing camshaft - ve‐

hicles without particulate filter
2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing and
installing camshaft .
4.2.2 Removing and installing camshaft - ve‐

hicles with particulate filter
Removing


sions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing camshaft .
Installing
Additional work:
Tightening torques
15 ; Cylinder head; Exploded view - cylinder head
4.3 Installing ball for slider

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Installing ball for
slider .
4.4 Removing and installing actuators for

camshaft adjustment
installing actuators for camshaft adjustment .
4.5 Removing and installing camshaft con‐

trol valve 1 - N205-
Removing camshaft control valve 1 - N205-
Removing exhaust camshaft control valve 1 - N318-
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing camshaft control valve 1 - N205- .
Installing
Additional work:
Tightening torques
4. Valve gear 87
4.6 Removing and installing valve stem oil

seals
installing valve stem oil seals .

5 Inlet and exhaust valves

ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust valves .
5. Inlet and exhaust valves 89

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 90
⇒ “1.2 Engine oil”, page 90
⇒ “1.3 Removing and installing sump (bottom section)”,
page 90
⇒ “1.4 Removing and installing oil pump”, page 92
⇒ “1.5 Removing and installing sump (top section)”, page 92
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 92
1.1 Exploded view - sump/oil pump

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Exploded view
- sump/oil pump .
1.2 Engine oil

♦ Draining engine oil ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: draining
♦ Extracting engine oil ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: extracting
♦ Filling up with engine oil ⇒ Maintenance ; Booklet 830 ; Main‐
tenance; Engine oil: filling up
♦ Removing and installing oil filter element ⇒ Maintenance ;
Booklet 830 ; Maintenance; Engine oil: renewing oil filter
♦ Checking oil level ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: checking oil level and correcting if neces‐
sary ; ⇒ Technical data for engines; Rep. gr. 00 ; Overview
of engines; Overview of engines with adjustment values (oil
gauge tester T40178)
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .
1.3 Removing and installing sump (bottom

section)
Removing
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
noise insulation .
90 Rep. gr.17 - Lubrication

– Remove bolt -arrow- and move bracket -1- for electrical wiring
harness clear.
– Vehicles with natural gas system: Unscrew bolt -3- on both

sides and press coolant pipes upwards.
– If fitted, remove bolt -1- for support mounting (both sides).
– If fitted, remove bolt -2- for engine mounting (both sides).

– Support engine in installation position ⇒ page 62 .
1. Sump/oil pump 91
Caution

– Using spindle - 10-222A/11- -item 1-, raise engine through

distance -a-.
• Dimension -a- = 20 mm
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Re‐
moving and installing sump (bottom section) .
Installing
Additional work:
– Detach support bracket ⇒ page 62 .
Tightening torques
1.4 Removing and installing oil pump

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Removing and
installing oil pump .
1.5 Removing and installing sump (top sec‐

tion)
installing sump (top section) .
1.6 Removing and installing oil level and oil

temperature sender - G266-
installing oil level and oil temperature sender - G266- .

2 Engine oil cooler

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine oil
cooler .
2. Engine oil cooler 93

3 Crankcase breather
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Crankcase
breather .

4 Oil filter/oil pressure switches

⇒ “4.1 Exploded view - oil filter”, page 95
⇒ “4.2 Exploded view - oil pressure switches/oil pressure control”,
page 95
⇒ “4.3 Removing and installing oil pressure switch F22 ”,
page 95
⇒ “4.4 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 95
⇒ “4.5 Removing and installing stage 3 oil pressure switch F447
”, page 95
⇒ “4.6 Removing and installing valve for oil pressure control N428
”, page 97
⇒ “4.7 Removing and installing piston cooling jet control valve
N522 ”, page 97
⇒ “4.8 Checking oil pressure”, page 97
4.1 Exploded view - oil filter

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure switches;
Exploded view - oil filter .
4.2 Exploded view - oil pressure switches/oil

pressure control
2.0 ltr. TFSI, 4-valve; Rep. gr. 17 ; Oil filter/oil pressure switches;
Exploded view - oil pressure switches/oil pressure control .
4.3 Removing and installing oil pressure

switch - F22-
Removing and installing oil pressure switch - F22- .
4.4 Removing and installing oil pressure

switch for reduced oil pressure - F378-
Removing and installing oil pressure switch for reduced oil pres‐
sure - F378- .
4.5 Removing and installing stage 3 oil pres‐

sure switch - F447-
⇒ “4.5.1 Removing and installing stage 3 oil pressure switch F447
- vehicles without natural gas system”, page 95
⇒ “4.5.2 Removing and installing stage 3 oil pressure switch F447
- vehicles with natural gas system”, page 96
4.5.1 Removing and installing stage 3 oil pres‐

sure switch - F447- - vehicles without
natural gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Removing and installing stage 3 oil pressure switch - F447- .
4. Oil filter/oil pressure switches 95

4.5.2 Removing and installing stage 3 oil pres‐

sure switch - F447- - vehicles with nat‐
ural gas system
♦ Hose clamps up to 25 mm - 3094-
Procedure
– Clamp off coolant hose -1- with hose clamps up to 25 mm -
3094- .

Note
Place a cloth underneath to catch escaping coolant.
– Clamp off coolant hoses using hose clamps, up to 25 mm -

3094- , release hose clips -1 and 2- and disconnect hoses.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure
switches; Removing and installing stage 3 oil pressure switch -
F447- .
Installing
Additional work:
Note
♦ Do not reuse coolant.
4.6 Removing and installing valve for oil

pressure control - N428-
Removing and installing valve for oil pressure control - N428- .
4.7 Removing and installing piston cooling

jet control valve - N522-
Removing and installing piston cooling jet control valve - N522- .
4.8 Checking oil pressure

Checking oil pressure .
4. Oil filter/oil pressure switches 97

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 98
⇒ “1.2 Checking cooling system for leaks”, page 102
⇒ “1.3 Draining and filling cooling system”, page 102
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, equipment version
without auxiliary heater”, page 98
⇒ “1.1.2 Connection diagram - coolant hoses, equipment version
with auxiliary heater”, page 100
⇒ “1.1.3 Connection diagram - coolant hoses, vehicles with nat‐
ural gas system”, page 101
1.1.1 Connection diagram - coolant hoses, equipment version without auxiliary

heater
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Brown = Heating circuit
♦ Green = Coolant circuit for gearbox
♦ Arrows show direction of coolant flow.
98 Rep. gr.19 - Cooling

1 - Radiator
2 - Cylinder block
3 - Non-return valve
4 - Turbocharger
6 - Exhaust manifold
7 - Cylinder head
8 - Coolant temperature send‐
er - G62-
9 - Restrictors
10 - Non-return valves
11 - Coolant shut-off valve
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
12 - Heat exchanger for heater
13 - Coolant circulation pump -
V50-
14 - Coolant pump
15 - Thermostat
❑ For coolant circuit for
gearbox
❑ For equipment version
with dual clutch gearbox
16 - ATF cooler
17 - Continued coolant circula‐
tion pump - V51-
❑ For equipment version with dual clutch gearbox
18 - Restrictor
19 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks
20 - Coolant expansion tank
22 - Radiator outlet coolant temperature sender - G83-
23 - Actuator for engine temperature regulation - N493-
24 - Engine oil cooler
1. Cooling system/coolant 99
1.1.2 Connection diagram - coolant hoses, equipment version with auxiliary heat‐
er
Note

1 - Radiator
2 - Cylinder block
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictors
11 - Auxiliary heater
❑ With circulation pump -
V55-
12 - Heater coolant shut-off
valve - N279-
14 - Coolant pump
15 - Thermostat
❑ For coolant circuit for
gearbox
16 - ATF cooler
tion pump - V51-
18 - Restrictor
19 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks


1.1.3 Connection diagram - coolant hoses, vehicles with natural gas system
Note

1 - Radiator
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictor
12 - Filler cap
❑ Checking pressure re‐
lief valve ⇒ Servicing 4-
cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr.
19 ; Cooling system/
coolant; Checking cool‐
ing system for leaks
13 - Bleeder hole
15 - Heater coolant shut-off
valve - N279-
16 - Gas pressure regulator
❑ With high-pressure
valve for gas mode -
N372-

17 - Cooling flange
18 - Thermostat
❑ For coolant circuit for gearbox
19 - ATF cooler
20 - Continued coolant circulation pump - V51-
21 - Coolant pump
22 - Coolant circulation pump - V50-
1.2 Checking cooling system for leaks

2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Checking cooling system for leaks .
1.3 Draining and filling cooling system

♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Pipe for cooling system tester - V.A.G 1274/10-

♦ Cooling system charge unit - VAS 6096-

♦ Refractometer - T10007A-

Draining
– Vehicles with natural gas system: Release catches
-arrows B- and open cover -1- -arrow A-.
WARNING


expansion tank.
noise insulation .

WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.

– Vehicles with natural gas system: Release hose clip -2- and
detach coolant hose from coolant pipe -1-.

– Vehicles with dual clutch gearbox: Release hose clips

-arrows-, disconnect coolant hoses from ATF cooler and drain
off coolant (open heat insulation sleeve if fitted).
• Secure all hose connections with correct type of hose clips (as
– Connect coolant hoses (version with plug-in connectors)
⇒ page 142 .
Coolant specifications
ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant; Draining
and filling cooling system .
Recommended mixture ratio for coolant
Caution
Danger of corrosion damage if unsuitable mixtures of water

and coolant additives are used.
♦ Only use distilled water as this ensures optimum corrosion
protection.
• Coolant (40 %) and distilled water (60 %) for frost protection

to -25 °C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant ⇒ Electronic parts catalogue
Filling cooling system

• Do not reuse coolant.
– Fill reservoir of -VAS 6096- with 10 litres of premixed coolant
(according to recommended ratio; for recommended ratio see
⇒ page 105 ).
– To simplify filling procedure, place filled reservoir on as high a
surface as possible, e.g. on a workshop trolley or the engine
and gearbox jack.
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank -1-.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -2- into a small container -3-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -4- to compressed air supply.
• Pressure: 7 ... 10 bar.
– Open valves in coolant circuit; select 01 - Coolant circuit
bleeding routine in Guided Functions ⇒ vehicle diag‐
nostic tester .

– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- and adapter
-V.A.G 1274/8- .

Bleeding cooling system

– Close filler cap -1- on coolant expansion tank (make sure it
engages).
– Start engine.
Time period Engine speed Air conditioner/heater setting
3 minutes 2000 rpm • Air conditioning system
“OFF”, LED in AC button not
lit
• Heating at “HI”, select low‐
est possible blower speed
(= 0)
Until both Idling • Air conditioning system

large coolant “OFF”
hoses at ra‐
diator be‐ • Heating at “HI”
come warm
2 minutes 2000 rpm • Air conditioning system
“OFF”
• Heating at “HI”
– Switch off engine.

Checking coolant level
WARNING

Vehicles without natural gas system:

• The coolant level must be at the “MAX” marking when the en‐
gine is cold.
• The coolant level can be above the “MAX” marking when the
engine is warm.
– Top up with coolant again if necessary.


• The top edge (= MAX marking) of the float -1- must be flush
with the opening -arrow- on the coolant expansion tank when
the engine is cold.
• The top edge of the float may be above the opening on the
coolant expansion tank when the engine is at operating tem‐
perature.
– Top up with coolant again if necessary.
Tightening torques

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 109
⇒ “2.2 Exploded view - electric coolant pump”, page 109
⇒ “2.3 Exploded view - coolant temperature senders”,
page 111
⇒ “2.4 Removing and installing electric coolant pump”,
page 111
⇒ “2.5 Removing and installing coolant pump”, page 119
⇒ “2.6 Removing and installing toothed belt for coolant pump”,
page 120
⇒ “2.7 Removing and installing actuator for engine temperature
regulation N493 ”, page 122
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 123
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 124
2.1 Exploded view - coolant pump/thermo‐

stat
2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - coolant pump/thermostat .
2.2 Exploded view - electric coolant pump
2. Coolant pump/thermostat assembly 109

1 - Bolt
❑ 9 Nm
2 - Coolant circulation pump -
V50-
❑ Depending on version
❑ Removing and instal‐
ling:
♦ Vehicles without natural
gas system
⇒ “2.4.1 Removing and in‐
stalling coolant circulation
pump V50 - vehicles with‐
out natural gas system”,
page 111
♦ Vehicles with natural gas
system
stalling coolant circulation
pump V50 - vehicles with
natural gas system”,
page 112
tion pump - V51-
❑ Depending on vehicle
equipment
❑ Removing and instal‐
ling:
♦ Vehicles without natural
gas system
stalling continued coolant
circulation pump V51 - ve‐
hicles without natural gas
system”, page 114
♦ Vehicles with natural gas
system
⇒ “2.4.4 Removing and installing continued coolant circulation pump V51 - vehicles with natural gas system”,
page 116
4 - Bolt
❑ 9 Nm
5 - Rubber grommet
6 - Bolt
❑ 2.7 Nm
7 - Rubber grommet
8 - Bolt
❑ 2.7 Nm
9 - Bracket
❑ For electric coolant pumps
❑ Different versions available; for allocation refer to ⇒ Electronic parts catalogue

2.3 Exploded view - coolant temperature

senders
sembly; Exploded view - coolant temperature senders .
2.4 Removing and installing electric coolant

pump
⇒ “2.4.1 Removing and installing coolant circulation pump V50 -
vehicles without natural gas system”, page 111
⇒ “2.4.2 Removing and installing coolant circulation pump V50 -
vehicles with natural gas system”, page 112
⇒ “2.4.3 Removing and installing continued coolant circulation
pump V51 - vehicles without natural gas system”, page 114
⇒ “2.4.4 Removing and installing continued coolant circulation
pump V51 - vehicles with natural gas system”, page 116
2.4.1 Removing and installing coolant circula‐

tion pump - V50- - vehicles without nat‐
ural gas system
Removing

– Vehicles with particulate filter: Remove bolts -arrows- for

bracket -1-.
Note
– Clamp off coolant hoses using hose clamps up to 25 mm -

3094- , release hose clips -2- and disconnect hoses.
– Remove bolts -arrow- and detach coolant circulation pump -
V50- .
Installing
Note

Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 109
2.4.2 Removing and installing coolant circula‐

tion pump - V50- - vehicles with natural
gas system

Removing
– Detach electrical connectors -2- from bracket and unplug.
– Release fasteners -arrows-, detach engine control unit - J623-
-item 3- and place to one side.

Note

– Remove bolts -2- and detach coolant circulation pump - V50- .
Installing
Note

Tightening torques
2.4.3 Removing and installing continued cool‐

ant circulation pump - V51- - vehicles
without natural gas system

Removing
– Vehicles with particulate filter: Remove bolts -arrows- for
bracket -1-.

Note

– Remove bolts -arrow- and detach continued coolant circula‐
tion pump - V51- .
Installing
Note

Tightening torques
2.4.4 Removing and installing continued cool‐

ant circulation pump - V51- - vehicles
with natural gas system

Removing
system ⇒ page 2 .
cleanliness .
WARNING



Note

3094- , release hose clips -arrows- and disconnect hoses.
– Carefully unscrew union nuts -1, 2- so that residual gas can
escape; counterhold at connections with a suitable tool.
Caution
Risk of gas leaks in gas pressure pipe due to improper han‐

dling.
♦ Do not attempt to bend gas pressure pipe to a different
shape
– Unscrew union nut -1- and move natural gas low-pressure

pipe to one side.
– Unclip high-pressure pipe from retainers.
– Unscrew union nut -2- and disconnect high-pressure pipe
slightly from gas pressure regulator.
– Unplug electrical connectors:

1- For high-pressure valve for gas mode - N372-
2- For sensor module - GX23-
3- For coolant circulation pump - V50-
4- For continued coolant circulation pump - V51-
– Unscrew bolts -arrows- and remove pump unit with gas pres‐
sure regulator.
– Remove bolts -5- and detach continued coolant circulation
pump - V51- .
Installing
Note
– Install natural gas high-pressure pipe ⇒ page 194 .

ing battery .

WARNING

structed person.

WARNING

– Perform gas system inspection ⇒ Maintenance ; Booklet 830 ;

Maintenance; Natural gas system: checking for damage and
leaks .
Tightening torques
♦ ⇒ “6.1 Exploded view - gas pressure regulator”, page 194
2.5 Removing and installing coolant pump

Removing
– Drain coolant ⇒ page 102 .
– Remove coolant pipes (rear) ⇒ page 135 .
– Remove engine control unit - J623- ⇒ page 211 .


– Unplug electrical connectors -2 ... 5-.
– If necessary, move electrical wiring harness clear.

– Remove bolt -1- and push bracket -2- with engine wiring har‐
ness to one side. (Different versions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Removing and installing coolant pump .
Installing
Additional work:
Note
– Install rear coolant pipes ⇒ page 135 .

– Install engine control unit - J623- ⇒ page 211 .
2.6 Removing and installing toothed belt for

coolant pump

Removing
– Remove engine control unit - J623- ⇒ page 211 .
– Release hose clips -1, 2- and disconnect coolant hoses.

– If necessary, move electrical wiring harness clear.
– Remove bolt -1- and push bracket -2- with engine wiring har‐
ness to one side. (Different versions.)

– Lift retaining clips -1, 2-, disconnect coolant hoses and press
to one side.
mostat assembly; Removing and installing toothed belt for coolant
pump .
Installing
Additional work:
Note
– Install engine control unit - J623- ⇒ page 211 .

2.7 Removing and installing actuator for en‐

gine temperature regulation - N493-
Removing


move them clear.
switch - F66- .
mostat assembly; Removing and installing actuator for engine
temperature regulation - N493- .
Installing
Additional work:
Note
– Vehicles with natural gas system: Install battery tray ⇒ Elec‐

trical system; Rep. gr. 27 ; Battery; Removing and installing
battery tray .
2.8 Removing and installing coolant temper‐

ature sender - G62-
⇒ “2.8.1 Removing and installing coolant temperature sender G62
- vehicles without particulate filter”, page 123
⇒ “2.8.2 Removing and installing coolant temperature sender G62
- vehicles with particulate filter”, page 123
2.8.1 Removing and installing coolant temper‐

ature sender - G62- - vehicles without
particulate filter
sembly; Removing and installing coolant temperature sender -
G62- .
2.8.2 Removing and installing coolant temper‐

ature sender - G62- - vehicles with par‐
ticulate filter
Removing



2:
– Remove bolt -1- and move pressure differential sender for
particulate filter - G1037- clear.
All versions (continued):

– Remove bolt -1- and detach bracket.
mostat assembly; Removing and installing coolant temperature
sender - G62- .
Installing
Additional work:
Tightening torques
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-
Procedure
• Engine cold.


– Relieve residual pressure in cooling system by releasing fas‐

tener -arrow- and briefly opening filler cap -1- on coolant
expansion tank.
Radiator outlet coolant temperature sender - G83- - version 1:

Note
♦ Place a cloth underneath to catch escaping coolant.

♦ Renew O-ring after removal.
– Lift retaining clip -1- and pull out radiator outlet coolant tem‐
perature sender - G83- .

Radiator outlet coolant temperature sender - G83- - version 2:

Note
♦ Place a cloth underneath to catch escaping coolant.

– Unscrew bolt -1- and pull off radiator outlet coolant tempera‐
ture sender - G83- .
Both versions:
Note
Insert new coolant temperature sender into connection immedi‐

ately to avoid loss of coolant.

– Check coolant level ⇒ page 107 .
Tightening torques
19 ; Coolant pump/thermostat assembly; Exploded view -
coolant temperature senders

3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 127
⇒ “3.2 Removing and installing coolant pipes”, page 129
⇒ “3.3 Removing and installing coolant pipes for gearbox”,
page 136
3.1 Exploded view - coolant pipes

♦ Coolant pipes on engine ⇒ page 127
♦ Coolant pipes for gearbox ⇒ page 128
Note
The arrow markings on coolant pipes and on ends of hoses must align.
Coolant pipes on engine
1 - Bolt
❑ 9 Nm
2 - Coolant hose
3 - Coolant pipe (left-side)
able; for correct version
refer to ⇒ Electronic
parts catalogue
⇒ page 129
4 - Coolant hose
5 - Bolt
❑ 20 Nm
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 20 Nm
8 - Coolant pipe (right-side)
♦ ⇒ “3.2.2 Removing and in‐
stalling coolant pipe (right-
side) - vehicles with alter‐
nator”, page 130
♦ ⇒ “3.2.3 Removing and in‐
stalling coolant pipe (right-
side) - vehicles with starter-
alternator”, page 133
9 - O-ring
10 - Coolant hose
❑ To remove, fold back heat insulation sleeve and lift retaining clip
❑ Connecting ⇒ page 142
3. Coolant pipes 127

11 - O-ring
12 - Bolt
❑ 6 Nm
13 - Coolant hose
Vehicles with natural gas system: Coolant pipe (rear) - tightening

torque
– Tighten bolts -arrows- to 9 Nm.
Coolant pipes for gearbox
1 - Coolant hoses
2 - Coolant hoses
3 - Bolt
❑ 9 Nm
4 - Coolant pipes for gearbox
⇒ page 136
5 - Bolt
❑ 9 Nm

3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing coolant pipe (left-side)”,
page 129
⇒ “3.2.2 Removing and installing coolant pipe (right-side) - vehi‐
cles with alternator”, page 130
⇒ “3.2.3 Removing and installing coolant pipe (right-side) - vehi‐
cles with starter-alternator”, page 133
⇒ “3.2.4 Removing and installing rear coolant pipes - vehicles with
3.2.1 Removing and installing coolant pipe

(left-side)
Removing
WARNING



expansion tank.
Note
♦ Place a cloth under coolant pipe to catch escaping coolant.

♦ Illustration shows installation position on a vehicle without nat‐
ural gas system.
– Move electrical wiring clear.

– Remove bolts -1, 2-.
3094- , release hose clips -arrows- and disconnect hoses.
Installing
Note

Tightening torques

(right-side) - vehicles with alternator

♦ Socket Torx T30 - T10405-
Removing
Note
Re-install all heat insulation sleeves in the same locations when

installing.

– Vehicles without natural gas system: Remove front silencer
⇒ page 223 .
– Vehicles with natural gas system: Remove front exhaust pipe
⇒ page 221 .
– Remove nut -2- from underneath.
– Remove air cleaner housing ⇒ page 178 .


– Remove nuts -1- from above and move catalytic converter to‐
wards rear.
– Remove bolt -arrow- and detach crankcase breather pipe from

turbocharger.

– Fold back heat insulation sleeve, lift retaining clip -2- and dis‐
connect coolant hose.
– Release hose clip -3- and disconnect coolant hose.
– Remove bolts -arrows- and -1-, detach coolant pipe (right-
side) from cylinder block and remove coolant pipe.
Installing
Note


Note

Tightening torques
21 ; Turbocharger; Exploded view - turbocharger

(right-side) - vehicles with starter-alter‐
nator

Removing
Note
Re-install all heat insulation sleeves in the same locations when

installing.
– Remove catalytic converter ⇒ Servicing 4-cylinder engine, 2.0

– Fold back heat insulation sleeve, lift retaining clip -2- and dis‐
connect coolant hose.
– Release hose clip -3- and disconnect coolant hose.
– Remove bolts -arrows- and -1-, detach coolant pipe (right-
side) from cylinder block and remove coolant pipe.
Installing
Note


Note

Tightening torques
21 ; Turbocharger; Exploded view - turbocharger

3.2.4 Removing and installing rear coolant

pipes - vehicles with natural gas system
Removing
– Release catches -arrows B- and open cover -1- -arrow A-.
WARNING



expansion tank.
Note

– Release hose clips -2- and disconnect coolant hoses.
– Unscrew bolts -arrows- and detach coolant pipes (rear).
Installing
Note

Tightening torques
♦ ⇒ Fig. ““Vehicles with natural gas system: Coolant pipe (rear)
- tightening torque”“ , page 128
3.3 Removing and installing coolant pipes

for gearbox



Removing
WARNING


expansion tank.
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
noise insulation .
– Vehicles with particulate filter: Remove front silencer
⇒ page 223 .

Note
– Clamp off coolant hoses using hose clamps up to 25 mm

-3094- , release hose clips -1- and disconnect hoses.
– Loosen hose clips -2- and detach coolant pipe.
Installing
Note

Tightening torques

4 Radiator/radiator fan
⇒ “4.1 Exploded view - radiator/radiator fan”, page 140
⇒ “4.2 Removing and installing radiator”, page 144
⇒ “4.3 Removing and installing radiator blind”, page 149
⇒ “4.4 Removing and installing radiator blind control motor”, page
150
⇒ “4.5 Removing and installing radiator cowl”, page 151
⇒ “4.6 Removing and installing radiator fan V7 ”, page 153
4.1 Exploded view - radiator/radiator fan

♦ Radiator - vehicles without natural gas system ⇒ page 140
♦ Radiator - vehicles with natural gas system ⇒ page 141
♦ Radiator blind ⇒ page 142
♦ Radiator cowl and radiator fan ⇒ page 143
Radiator - vehicles without natural gas system
1 - Radiator
⇒ page 144
❑ If renewed, change
coolant in entire system
2 - Plug
❑ Do not unscrew
❑ Not available as sepa‐
rate part
3 - O-ring
❑ Not available as sepa‐
rate part
4 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 142
5 - O-rings
6 - Coolant hose
tach
❑ Connecting
⇒ page 142
7 - Coolant pipe
❑ To coolant expansion
tank
❑ Press release ring to de‐
tach
❑ Connecting
⇒ page 142
8 - O-ring

9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
❑ Use screwdriver to release and pull off
12 - Air duct
13 - Rubber bush
❑ For radiator
14 - Radiator bracket
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
Radiator - vehicles with natural gas system
1 - Coolant hose
tach
❑ Connecting
⇒ page 142
2 - O-ring
3 - Drain plug
❑ 1.5 … 3 Nm
4 - O-ring
5 - Coolant hose
tach
❑ Connecting
⇒ page 142
6 - O-ring
7 - Radiator
⇒ page 144
❑ If renewed, change
coolant in entire system
8 - Rubber mounting
❑ For radiator
9 - Sleeve
10 - Retaining pin
❑ Use screwdriver to re‐
lease and pull off
4. Radiator/radiator fan 141

11 - Coolant pipe
❑ To coolant expansion tank
12 - Air duct
13 - Rubber bush
❑ For radiator
14 - Radiator bracket
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
Connecting coolant hose with plug-in connector
Note
If damaged, renew retaining clip -4-.
– Remove old O-ring -2- from coolant hose -3-.

– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto coolant pipe -1- until it engages with
a click.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Radiator blind

1 - Air duct
2 - Radiator blind
⇒ page 149
3 - Bolt
❑ 5 Nm
4 - Fin
5 - Bracket
6 - Bolt
❑ 8 Nm
7 - Carrier
8 - Bolt
❑ 2.5 Nm
9 - Connecting piece
10 - Radiator blind control mo‐
tor - V544-
⇒ page 150
11 - Speed nut
12 - Air duct
13 - Spring element
14 - Bolt
❑ 8 Nm
Radiator cowl and radiator fan

1 - Radiator cowl
⇒ page 151
2 - Bolt
❑ 5 Nm
3 - Radiator fan - V7-
❑ With radiator fan control
unit - J293-
⇒ page 153
4 - Air flow flap
able ⇒ Electronic parts
catalogue
4.2 Removing and installing radiator
Note
The radiator must be removed and installed together with the ra‐
diator cowl.


♦ Assembly tool - T10118-
Removing
WARNING

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.

noise insulation .
Equipment version without radiator blind:
– Remove bracket for bumper cover together with impact bar ⇒
General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover .
Equipment version with radiator blind:
– Remove impact bar together with radiator blind ⇒ page 149 .
– A4: Remove headlight (left-side) ⇒ Electrical system; Rep. gr.
94 ; Headlights; Removing and installing headlights .


– Unplug electrical connector -arrow- for radiator fan.


– Vehicles with natural gas system: Detach air duct -2-.


– Remove charge air cooler ⇒ page 158 .
– Unplug electrical connector -2- for high-pressure sender -

G65- .
Caution
Risk of irreparable damage to radiator if handled incorrectly.

♦ If fasteners are damaged, radiator must be renewed.
– Carefully release fasteners on both sides -arrows-.
Caution
Risk of damage to refrigerant lines and hoses

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Disengage condenser -1- from radiator and tie condenser up

to one side.
– Vehicles without natural gas system: Lift retaining clips -1, 2-,
detach coolant connection from radiator and move connection
clear.

– Vehicles with natural gas system: Detach coolant connection

and coolant hose from radiator (lift retaining clip -1- and open
hose clip -2-).

– Detach radiator.

– Press locking tabs on left and right sides of radiator cowl to‐
gether -arrow- and lift radiator cowl off radiator.
Installing
Note
If there are slight impressions on the fins, refer to ⇒ Servicing 4-

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes;
Installing radiators and condensers
– Install charge air cooler ⇒ page 158 .

– Install headlight ⇒ Electrical system; Rep. gr. 94 ; Headlights;
Removing and installing headlights .
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fan”, page 140
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier;
Exploded view - lock carrier
4.3 Removing and installing radiator blind

Removing
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing impact bar .
WARNING
Risk of injury if components are triggered inadvertently.

♦ Before handling pyrotechnic components (e.g. plugging in
the electrical connector) the mechanic must discharge any
static electricity. This can be done by briefly touching the
door striker plate, or similar.

– Equipment version with pedestrian protection: Unplug electri‐

cal connector -1- at crash sensor for pedestrian protection and
move electrical wiring harness -2- clear.
– Unplug electrical connector -3- and move clear.

– Remove bolts -arrows- (left and right).
– Slide mounting bracket -2- with Bowden cable for operating
lever for arrester towards lock carrier.
– Detach radiator blind (top) -1- towards front.
Installing
– Install impact bar ⇒ General body repairs, exterior; Rep. gr.
63 ; Bumper (front); Removing and installing impact bar .
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Bonnet; Ex‐
ploded view - Bowden cable
4.4 Removing and installing radiator blind

control motor
Removing

– Take electrical connector -1- for radiator blind control motor -

V544- out of bracket and unplug it.
– Carefully press connecting piece -3- upwards/downwards and
unscrew bolts -arrows-.
– Detach control motor with bracket -2- and fins.
– Unplug electrical connector -4- at radiator blind control motor

- V544- -item 3-.
– Remove bolts -2-.
– Carefully unclip coupling -1- -arrow A- and at the same time,
detach it from bracket -5- together with control motor
-arrow B-.
– Pull off and detach control motor from coupling.
Installing
– Bring radiator blind control motor - V544- with bracket and fins
into installation position:
– Insert fins -1- one after another on both sides into holes on
radiator blind -2- -left arrows-.
– On both sides, guide fins into recesses on radiator blind
-right arrows-.
Remaining installation steps are carried out in reverse sequence;
note the following:
Tightening torques
4.5 Removing and installing radiator cowl

Removing
noise insulation .
– Remove charge air cooler ⇒ page 158 .

WARNING

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.
– Unplug electrical connector -arrow- for radiator fan.
– Unclip air duct (bottom) -arrow-.
– Unplug electrical connector -2- and move coolant hose clear

at longitudinal member. (Different versions.)

– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow-, lift radiator cowl off radiator and remove
from below.
Installing
– Install charge air cooler ⇒ page 158 .
Tightening torques
4.6 Removing and installing radiator fan -

V7-
Removing
– Remove radiator cowl ⇒ page 151 .
– Move electrical wiring harness clear.
– Unscrew bolts -arrows- and remove radiator fan.
Caution
Risk of noise due to imbalance in fan wheel.

♦ Do not remove balancing clamps from fan wheel.
Installing
– Install radiator cowl ⇒ page 151 .
Tightening torques

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 154
⇒ “1.2 Removing and installing turbocharger”, page 154
1.1 Exploded view - turbocharger

2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Exploded view
- turbocharger .
1.2 Removing and installing turbocharger

⇒ “1.2.1 Removing and installing turbocharger - vehicles with al‐
ternator”, page 154
⇒ “1.2.2 Removing and installing turbocharger - vehicles with
starter-alternator”, page 155
1.2.1 Removing and installing turbocharger -

vehicles with alternator
Removing
– Vehicles without natural gas system: Loosen bolted connec‐

tions -arrows- and push clamp towards rear.
154 Rep. gr.21 - Turbocharging/supercharging

– Vehicles with natural gas system: Loosen clamp -arrow- and

detach front exhaust pipe from front silencer.
Caution

– Lower front silencer/front exhaust pipe -2- slightly and secure

it with a cable tie -1-, as shown.
– Remove nut -2- from underneath.

– Remove air cleaner housing ⇒ page 178 .
– Remove nuts -1- from above and push catalytic converter to‐
wards rear.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Re‐
moving and installing turbocharger .
Installing
Additional work:
Tightening torques
1.2.2 Removing and installing turbocharger -

vehicles with starter-alternator
Removing
– Remove catalytic converter ⇒ Servicing 4-cylinder engine, 2.0
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Re‐
moving and installing turbocharger .
1. Turbocharger 155
Installing
Additional work:

2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 157
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 158
⇒ “2.3 Removing and installing charge air cooler”, page 158
⇒ “2.4 Removing and installing charge pressure sender G31 ”,
page 159
⇒ “2.5 Checking charge air system for leaks”, page 160
2.1 Exploded view - charge air system
1 - Charge air cooler

⇒ page 158
❑ If there are slight im‐
pressions on the fins, re‐
fer to ⇒ Servicing 4-
cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr.
00 ; Repair notes; Instal‐
ling radiators and con‐
densers
2 - Air hose
❑ Must be free of oil and
grease when installing
3 - From turbocharger
4 - Bolt
❑ Repair method if fasten‐
er breaks off
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
❑ 7 Nm
5 - Charge pressure sender -
G31-
⇒ page 159
6 - O-ring
7 - To intake manifold
8 - Seal
❑ Renew if damaged
9 - Air pipe
❑ Must be free of oil and grease when installing
10 - Seal
2. Charge air system 157

2.2 Exploded view - hose connections for

charge air system
2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system; Exploded
view - hose connections for charge air system .
2.3 Removing and installing charge air cool‐

er
Removing
Note
Observe rules for cleanliness ⇒ Servicing 4-cylinder engine, 2.0

ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for cleanli‐
ness .
– Remove lock carrier cover, air intake grille (left and right) and
cover .

– Release hose clip -1- on both sides and detach air pipe from
charge air cooler.
Caution
Risk of irreparable damage to charge air cooler.

♦ The charge air cooler must be renewed if the fasteners are
damaged.
– Release fasteners -arrows- on both sides and disengage

charge air cooler from radiator.
– Take out charge air cooler from underneath.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ Servicing

4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair
notes; Installing radiators and condensers
– Install lock carrier cover, air intake grille (left and right) and
cover .
Tightening torques
charge air system
2.4 Removing and installing charge pres‐

sure sender - G31-
Removing
– Vehicles with natural gas system: Remove noise insulation
(front) ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise
insulation; Removing and installing noise insulation .


– Turn charge pressure sender - G31- -item 2- anti-clockwise
and pull it out of air pipe.
Installing
– Place charge pressure sender - G31- in installation position
and turn it clockwise until it engages.
Note

♦ If fastener on air pipe has broken off, secure charge pressure
positioner - G31- with two bolts, refer to ⇒ Electronic parts
catalogue .
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 157
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
♦ End seal - V.A.G 1687/6- and adapters -V.A.G 1687/3- , -

V.A.G 1687/13-2- , -V.A.G 1687/15-

Procedure
Note
Observe rules for cleanliness ⇒ Servicing 4-cylinder engine, 2.0

ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for cleanli‐
ness .

– Loosen hose clips -arrows-.

– Disconnect vacuum hose -2- and remove air pipe -1-.
– Fit end seal - V.A.G 1687/6- and adapter - V.A.G 1687/13-2-

on turbocharger.
Caution



– Loosen clamp (front) -arrows- and push towards rear.

– Loosen clamp -arrow-.

– Detach front exhaust pipe from front silencer.

– Lower front silencer -2- slightly and secure it with a cable tie
-1-, as shown. (Shown on a vehicle without natural gas sys‐
tem.)

– Seal off front silencer with adapter - V.A.G 1687/3- and adapt‐
er - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- with connec‐

tion -5- to end seal - V.A.G 1687/6- .
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system;
Checking charge air system for leaks .
Assembling
Additional work:
Tightening torques
charge air system

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 164
1.1 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment, vehicles with‐
out natural gas system
1 - Lambda probe 1 after cata‐

lytic converter - GX7-
❑ Comprises:
♦ Lambda probe after catalyt‐
ic converter - G130-
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
❑ Fitting location
⇒ page 168
2 - Coolant shut-off valve -
N82-
❑ On equipment version
with auxiliary heating:
heater coolant shut-off
valve - N279-
3 - Gear detection sensor -
G604-
with manual gearbox
⇒ page 168
4 - Pressure differential sender
for particulate filter - G1037-
❑ Vehicles with particulate
filter only
❑ Exploded view ⇒ Serv‐
icing 4-cylinder engine,
2.0 ltr. 4-valve TFSI;
Rep. gr. 24 ; Lambda
probe; Exploded view -
Lambda probe
5 - Vacuum sender - G608-
6 - Accelerator position sender
- G79- and accelerator position sender 2 - G185-
❑ Fitting location ⇒ page 167
7 - Brake light switch - F-
8 - Coolant circulation pump - V50- , continued coolant circulation pump - V51-
❑ Exploded view ⇒ page 109
9 - Clutch position sender - G476-
❑ With clutch pedal switch - F36- / clutch pedal switch for engine start - F194-
164 Rep. gr.24 - Mixture preparation - injection

❑ For equipment version with manual gearbox

❑ Exploded view ⇒ Gearbox; Rep. gr. 30 ; Clutch mechanism; Exploded view - pedal cluster
10 - Engine control unit - J623-
12 - Charge pressure sender - G31-
13 - Left electrohydraulic engine mounting solenoid valve - N144-
14 - Right electrohydraulic engine mounting solenoid valve - N145-
15 - Lambda probe 1 before catalytic converter - GX10-
❑ Comprises:
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Exploded
view - Lambda probe
16 - Air mass meter - G70-
Overview of fitting locations - engine compartment, vehicles with

natural gas system
1. Injection system 165

1 - Lambda probe 1 after cata‐

lytic converter - GX7-
❑ Comprises:
♦ Lambda probe after catalyt‐
ic converter - G130-
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
⇒ page 168
2 - Coolant shut-off valve -
N82-
❑ On equipment version
with auxiliary heating:
heater coolant shut-off
valve - N279-
3 - Gear detection sensor -
G604-
with manual gearbox
⇒ page 168
4 - Brake servo pressure sen‐
sor - G294-
5 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ page 167
6 - Brake light switch - F-
⇒ page 167
7 - Gas pressure regulator/
sensor module - GX23-
❑ Removing and installing ⇒ “7.7 Removing and installing sensor module GX23 ”, page 203
8 - Clutch position sender - G476-
❑ With clutch pedal switch - F36- / clutch pedal switch for engine start - F194-
❑ For equipment version with manual gearbox
❑ Exploded view ⇒ Gearbox; Rep. gr. 30 ; Clutch mechanism; Exploded view - pedal cluster
9 - Coolant circulation pump - V50-
10 - Continued coolant circulation pump - V51-
12 - Charge pressure sender - G31-

14 - Left electrohydraulic engine mounting solenoid valve - N144-

15 - Lambda probe 1 before catalytic converter - GX10-
❑ Comprises:
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Exploded
view - Lambda probe
16 - Right electrohydraulic engine mounting solenoid valve - N145-
Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-
♦ Integrated in accelerator pedal module -3-. Accelerator posi‐
tion senders cannot be renewed separately if defective.
Exploded view ⇒ Fuel supply system; Rep. gr. 20 ; Accelerator
mechanism; Exploded view - accelerator pedal module
Fitting location of brake light switch - F-

♦ In engine compartment on brake master cylinder
1- Electrical connector for brake light switch - F-
Exploded view ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake
master cylinder; Exploded view - brake servo/brake master cyl‐
inder

Fitting location of gear detection sensor - G604-

♦ At top right of manual gearbox
1- Gear detection sensor - G604-
Removing and installing ⇒ Gearbox; Rep. gr. 34 ; Selector
mechanism ; Removing and installing gear detection sensor -
G604-
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ In coolant connection on radiator at bottom left. (Different ver‐
sions.)
2 - Electrical connector for radiator outlet coolant temperature
sender - G83-
Exploded view ⇒ page 111 .
Fitting location of Lambda probe 1 after catalytic converter - GX7-

♦ In catalytic converter
1- Lambda probe 1 after catalytic converter - GX7-
2- Electrical connector for Lambda probe 1 after catalytic con‐
verter - GX7-
Note:
Installation position varies depending on model and version.
Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve
TFSI; Rep. gr. 24 ; Lambda probe; Exploded view - Lambda
probe
Fitting location of electrohydraulic engine mounting solenoid

valves -N144- / -N145-
♦ Integrated in engine mounting. It cannot be renewed sepa‐
rately if defective.
Pfeil - Electrical connector for left electrohydraulic engine mount‐
ing solenoid valve - N144-
Removing and installing
⇒ “2.3 Removing and installing engine mountings”, page 63

Fitting locations on vehicles with natural gas system - gas pres‐

sure regulator/ sensor module - GX23- , coolant circulation pump
- V50- , continued coolant circulation pump - V51-
♦ On left of engine compartment
1- Electrical connector for gas pressure regulator with high-
pressure valve for gas mode - N372-
2- Electrical connector for sensor module - GX23-
Exploded view
⇒ “6.1 Exploded view - gas pressure regulator”, page 194 .
3 - Electrical connector for coolant circulation pump - V50-
4 - Electrical connector for continued coolant circulation pump -
V51-
Exploded view
⇒ “2.2 Exploded view - electric coolant pump”, page 109 .
Overview of fitting locations - engine (from above), vehicles with‐

out natural gas system
1 - Ignition coil 1 with output

stage - N70-
Rep. gr. 28 ; Ignition
system; Exploded view -
ignition system
stage - N127-
ignition system
stage - N291-
ignition system
stage - N292-
ignition system
5 - Hall sender 3 - G300-
system; Exploded view - ignition system

6 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-

❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
❑ Integrated in high-pressure pump
7 - Injector 2, cylinder 4 - N535- , MPI
❑ Injector 2, cylinder 4 - N535-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded
view - fuel rail with injectors
9 - Fuel pressure sender for low pressure - G410- , MPI
10 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold
13 - Intake manifold flap potentiometer - G336-
14 - Activated charcoal filter solenoid valve 1 - N80-
Overview of fitting locations - engine (from above), vehicles with

natural gas system


stage - N70-
ignition system
stage - N127-
ignition system
stage - N291-
ignition system
stage - N292-
ignition system
5 - Hall sender 3 - G300-
system; Exploded view - ignition system
6 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-
❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
❑ Integrated in high-pressure pump
7 - Fuel pressure sender for low pressure - G410-
8 - Gas injection valve 4 - N369-
❑ Exploded view ⇒ “5.1 Exploded view - gas rail”, page 189
9 - Gas injection valve for cylinder 3 - N368-
10 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
11 - Gas rail temperature and pressure sensor - GX21-


14 - Intake manifold flap potentiometer - G336-
15 - Activated charcoal filter solenoid valve 1 - N80-
Overview of fitting locations - engine (inlet side)
1 - Oil level and oil temperature

sender - G266-
Rep. gr. 17 ; Sump/oil
pump; Exploded view -
sump/oil pump
2 - Actuator for engine temper‐
ature regulation - N493-
Rep. gr. 19 ; Coolant
pump/thermostat as‐
sembly; Exploded view -
coolant pump/thermo‐
stat
3 - Injector, cylinder 2 - N31- ,
FSI
Rep. gr. 24 ; Injectors;
Exploded view - fuel rail
with injectors
4 - Injector, cylinder 1 - N30- ,
FSI
Rep. gr. 24 ; Injectors;
Exploded view - fuel rail
with injectors
5 - Fuel pressure sender -
G247-
icing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view - fuel rail with injectors
6 - Throttle valve module - GX3-
❑ Comprises:
♦ Throttle valve module - J338-
♦ Throttle valve drive (for electric throttle) - G186-
♦ Throttle valve drive angle sender - G187-
♦ Throttle valve drive angle sender 2 - G188-

7 - Actuator 1 for camshaft adjustment - F366- (for cylinder No. 1)

❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
15 - Hall sender - G40-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Ex‐
ploded view - ignition system
16 - Intake manifold flap valve - N316-
17 - Injector, cylinder 4 - N33- , FSI
18 - Injector, cylinder 3 - N32- , FSI
19 - Stage 3 oil pressure switch - F447-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure
switches; Exploded view - oil pressure switches/oil pressure control
20 - Engine speed sender - G28-
21 - Knock sensor 1 - G61-
Overview of fitting locations - engine (exhaust side)


er - G62-
❑ Exploded view
⇒ “2.3 Exploded view -
coolant temperature
senders”, page 111
2 - Charge pressure positioner
- V465- with position sender for
charge pressure positioner -
G581-
❑ Integrated in turbo‐
charger
3 - Turbocharger air recircula‐
tion valve - N249-
Rep. gr. 21 ; Turbo‐
charger; Exploded view
- turbocharger
Overview of fitting locations - engine (view from front), vehicles

with alternator

1 - Exhaust camshaft control

valve 1 - N318-
Rep. gr. 15 ; Timing
chain cover; Exploded
view - timing chain cover
2 - Camshaft control valve 1 -
N205-
3 - Oil pressure switch - F22-
Rep. gr. 17 ; Oil filter/oil
pressure switches; Ex‐
ploded view - oil pres‐
sure switches/oil pres‐
sure control
4 - Oil pressure switch for re‐
duced oil pressure - F378-
sure control
5 - Piston cooling jet control
valve - N522-
6 - Valve for oil pressure control - N428-
Overview of fitting locations - engine (view from front), vehicles

with starter-alternator

1 - Oil pressure switch - F22-

sure control
2 - Exhaust camshaft control
valve 1 - N318-
3 - Camshaft control valve 1 -
N205-
4 - Piston cooling jet control
valve - N522-
sure control
5 - Oil pressure switch for re‐
duced oil pressure - F378-
6 - Valve for oil pressure control - N428-

2 Air cleaner
⇒ “2.1 Exploded view - air cleaner housing”, page 177
⇒ “2.2 Removing and installing air cleaner housing”, page 178
2.1 Exploded view - air cleaner housing
1 - Snow screen
❑ Country-specific version
2 - Air duct
❑ On lock carrier
❑ Remove any salt depos‐
its or dirt
3 - Water drain
❑ Clean
4 - Mounting
❑ For air cleaner housing
5 - Sealing element
6 - Air duct
❑ For country-specific ver‐
sion with variable intake
manifold change-over
valve - N335-
❑ Not fitted after air clean‐
er (bottom section) has
been renewed
⇒ page 180
7 - Air cleaner (bottom section)
❑ Remove any salt depos‐
its or dirt
❑ Country-specific ver‐
sion: variable intake
manifold changeover
valve - N335- is not fitted
after air cleaner (bottom
section) has been re‐
newed ⇒ page 180
⇒ page 178
8 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Change intervals ⇒ Maintenance tables
❑ Removing and installing ⇒ Maintenance ; Booklet 830 ; Maintenance; Air cleaner: renewing filter element
and cleaning housing
9 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
10 - Air cleaner (top section)
❑ Remove any salt deposits or dirt
❑ Removing and installing ⇒ Maintenance ; Booklet 830 ; Maintenance; Air cleaner: renewing filter element
and cleaning housing
2. Air cleaner 177

11 - Seal
❑ Check for damage
12 - Bolt
❑ Thread-forming
❑ 3.5 Nm
14 - Air pipe
❑ Observe installation markings
❑ Tightening torque for screw-type clips ⇒ page 158
15 - Bolt
❑ Thread-forming
❑ 1.5 Nm
16 - Heat shield
17 - Air duct
❑ On lock carrier
❑ Remove any salt deposits or dirt
18 - Bolt
❑ Thread-forming
❑ 2.5 Nm
2.2 Removing and installing air cleaner

housing
Removing

Vehicles with air filter bypass flap valve - N275- :

– Remove wheel spoiler (front right) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Unplug electrical connector -2- for air filter bypass flap valve -
N275- .
– Detach water drain -1- downwards -arrow-.

– Remove bolts -arrows- and detach air duct -2- from lock car‐
rier.
2. Air cleaner 179


– Seal off turbocharger with sealing plug (thoroughly cleaned)
from engine bung set - VAS 6122- .
Installing
Note
♦ The air cleaner housing must always be clean.

♦ Use soap solution when fitting air hose.
♦ Country-specific version:
variable intake manifold changeover valve - N335- is not fitted
after renewal; fit a mating plug onto electrical connector in
electrical wiring harness ⇒ Electronic parts catalogue .
– Check water drain in air cleaner (bottom section) for dirt and
other obstructions and clean if necessary.
– Check for dirt in air duct going from lock carrier to air cleaner
housing.
Tightening torques
charge air system

3 Intake manifold
⇒ “3.1 Exploded view - intake manifold”, page 181
⇒ “3.2 Removing and installing intake manifold”, page 181
⇒ “3.3 Removing and installing throttle valve module GX3 ”, page
185
3.1 Exploded view - intake manifold

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Exploded view
- intake manifold .
3.2 Removing and installing intake manifold

⇒ “3.2.1 Removing and installing intake manifold - vehicles with‐
out particulate filter”, page 181
⇒ “3.2.2 Removing and installing intake manifold - vehicles with
⇒ “3.2.3 Removing and installing intake manifold - vehicles with
3.2.1 Removing and installing intake manifold

- vehicles without particulate filter
Removing
– Use assembly tool - T10118- to release electrical connector
for fuel pressure sender - G247- and unplug it.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Re‐
moving and installing intake manifold .
Installing
Additional work:
3. Intake manifold 181


- vehicles with particulate filter
Removing
sender 3 - G495- / exhaust gas temperature sender 4 - G648-
out of bracket and unplug.
sions.)
– Unplug electrical connector -1- for exhaust gas temperature

sender 3 - G495- and move wiring clear.

1:
– Move bracket with pressure differential sender clear at intake
manifold -arrow-.
Installing
Additional work:
Tightening torques

- vehicles with natural gas system

Removing
system ⇒ page 2 .
cleanliness .
WARNING



– Use assembly tool - T10118- to release electrical connector

for fuel pressure sender - G247- and unplug it.

Installing
Additional work:
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
WARNING

structed person.

WARNING



3.3 Removing and installing throttle valve

module - GX3-
⇒ “3.3.1 Removing and installing throttle valve module GX3 - ve‐
hicles without natural gas system”, page 185
⇒ “3.3.2 Removing and installing throttle valve module GX3 - ve‐
3.3.1 Removing and installing throttle valve

module - GX3- - vehicles without natural
gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Removing and
installing throttle valve module - GX3- .
3.3.2 Removing and installing throttle valve

module - GX3- - vehicles with natural
gas system
Removing
moving and installing throttle valve module - GX3- .
Installing
Additional work:

4 Injectors
⇒ “4.1 Exploded view - fuel rail with injectors”, page 186
⇒ “4.2 Removing and installing fuel rail”, page 186
⇒ “4.3 Removing and installing injectors”, page 186
⇒ “4.4 Cleaning injectors”, page 188
4.1 Exploded view - fuel rail with injectors

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view - fuel
rail with injectors .
4.2 Removing and installing fuel rail

⇒ “4.2.1 Removing and installing fuel rail - vehicles with alterna‐
tor”, page 186
⇒ “4.2.2 Removing and installing fuel rail - vehicles with starter-
alternator”, page 186
4.2.1 Removing and installing fuel rail - vehi‐

cles with alternator
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing and in‐
stalling fuel rail .
4.2.2 Removing and installing fuel rail - vehi‐

cles with starter-alternator
Removing
– Unplug electrical connector -arrow- for fuel pressure sender -
G247- .
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing
and installing fuel rail .
4.3 Removing and installing injectors

⇒ “4.3.1 Removing and installing injectors - vehicles with FSI en‐
gine”, page 186
⇒ “4.3.2 Removing and installing injectors - vehicles with MPI en‐
gine”, page 187
⇒ “4.3.3 Removing and installing injector sleeves - vehicles with
4.3.1 Removing and installing injectors - ve‐

hicles with FSI engine
stalling injectors .

4.3.2 Removing and installing injectors - ve‐

hicles with MPI engine
stalling injectors .
4.3.3 Removing and installing injector sleeves

- vehicles with natural gas system
♦ Puller -T40360-
♦ Thrust piece - T40361-
Note
♦ The protective sleeve must be renewed if the FSI injector or

the support has been renewed.
♦ It is not necessary to renew the protective sleeve if the re‐
moved FSI injector is re-installed.
♦ The FSI injector can be re-installed if the protective sleeve has
been renewed.
4. Injectors 187
Preparing puller -T40360-

– Turn nut -1- anti-clockwise -arrow B- by hand as far as stop on
circlip -2- (counterhold at hexagon head -4-).
– Turn nut -3- clockwise -arrow A- by hand as far as stop on
circlip -2- (counterhold at hexagon head -4-).
Removing
• FSI injectors removed ⇒ Servicing 4-cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr. 24 ; Injectors; Removing and installing
injectors .
– Insert puller -T40360- all the way into relevant hole for injector.
Note
♦ Use a torque wrench to fix the injector sleeve in position.

♦ Set torque wrench to 5 Nm.
– To fix injector sleeve in position, turn nut -2- clockwise

-arrow A- until limit torque is reached (counterhold at hexagon
head -1-).
– To pull out injector sleeve, turn nut -3- anti-clockwise
-arrow B- (counterhold at hexagon head -1-).
Installing
– Use thrust piece - T40361- to carefully insert injector sleeve
-1- as far as it will go into hole in cylinder head -2-.
4.4 Cleaning injectors

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Cleaning injectors .

5 Gas injection valves

⇒ “5.1 Exploded view - gas rail”, page 189
⇒ “5.2 Removing and installing gas rail with gas injection valve
N366 / N367 / N368 / N369 ”, page 190
⇒ “5.3 Removing and installing gas injection valve”, page 193
5.1 Exploded view - gas rail
1 - O-ring
❑ Must be installed dry
2 - Gas injection valve
⇒ “5.2 Removing and in‐
stalling gas rail with gas
injection valve N366 /
N367 / N368 / N369 ”,
page 190
❑ After removing, perform
leak test on low-pres‐
sure section of natural
gas system ⇒ Natural
gas engines - General
information; Rep. gr.
00 ; Checking natural
gas system
3 - O-ring
❑ Must be installed dry
4 - Retaining clip
❑ Ensure it is positioned
correctly on gas injec‐
tion valve and fuel rail
5 - Gas rail
❑ After removing, perform
leak test on low-pres‐
sure section of natural
gas system ⇒ Natural
gas engines - General
information; Rep. gr.
00 ; Checking natural
gas system
6 - Bolt
❑ 7 Nm
7 - Connection
❑ Not available as replacement part
8 - Natural gas low-pressure pipe
❑ Installation position ⇒ page 190
❑ Screw on union nut by hand until it makes contact
❑ 5 Nm +70°
5. Gas injection valves 189

9 - Gas rail temperature and pressure sensor - GX21-

⇒ “7.6 Removing and installing gas rail temperature and pressure sensor GX21 ”, page 202
❑ Lubricate taper seal and thread lightly with silicone-free oil
❑ After removing, perform leak test on low-pressure section of natural gas system ⇒ Natural gas engines
- General information; Rep. gr. 00 ; Checking natural gas system
❑ Counterhold at connection with a suitable tool to tighten on gas rail
❑ Tighten in stages:
• Pre-tighten to 27 Nm
• Turn back by 60°
• Final tightening torque: 34 Nm
Natural gas low-pressure pipe - installation position

– Bring natural gas low-pressure pipe into installation position
and screw on union nut -2- by hand until it makes contact.
• Locating element -4- must make contact with engine lifting eye
-3-.
– Tighten union nut; to do so, counterhold at connection -1- with
a suitable tool.
5.2 Removing and installing gas rail with

gas injection valve -N366- / -N367- / -
N368- / -N369-
Removing
system ⇒ page 2 .
cleanliness .

WARNING


– Move electrical wiring clear at intake manifold.
– Detach vacuum line -1- and coolant line -2- from intake mani‐
fold.
– Unplug electrical connectors -4, 5-.
– Unscrew bolt -arrow- using socket Torx T30 - T10405- and

detach bracket -1- for electrical connectors.
– Unscrew union nut -2- for natural gas low-pressure pipe; to do

so, counterhold at connection -1- with a suitable tool.

– Move electrical wiring harness -1- clear at engine lifting eye.

– Unscrew bolts -arrows- for gas rail.
– Carefully lift out gas rail -2- with gas injection valves.
Installing
Note
Renew O-rings after removing.
– Lubricate O-rings with clean engine oil prior to installation.

– Press gas rail with gas injection valves by hand as far as it will
go into aperture of intake manifold (gas injection valves must
be free of oil and grease).
WARNING

structed person.

WARNING


Tightening torques
♦ ⇒ “5.1 Exploded view - gas rail”, page 189
24 ; Intake manifold; Exploded view - intake manifold

5.3 Removing and installing gas injection

valve
Removing
• Gas rail with gas injection valves -N366- / -N367- / -N368- / -
N369- removed ⇒ page 190
– Remove retaining clip -2- and detach gas injection valve -3-
from gas rail -1-.
2 - Retaining clip
3 - O-ring
5 - O-ring
Installing
Note
Renew retaining clips and O-rings after removal.
– Fit O-rings -3, 5- and check that they are seated correctly (O-
rings must be dry).
– Note correct installation position of retaining clip -2- relative to
gas injection valve -4-.
– Ensure that gas injection valve is seated correctly on connec‐
tion to gas rail -1-.

6 Gas pressure regulator

⇒ “6.1 Exploded view - gas pressure regulator”, page 194
⇒ “6.2 Removing and installing gas pressure regulator”,
page 195
6.1 Exploded view - gas pressure regulator
1 - Coolant hose
❑ To coolant expansion
tank
2 - Coolant hose
❑ From engine
3 - Natural gas low-pressure
pipe
⇒ page 195
❑ If leaks are present, un‐
screw union nut com‐
pletely and re-tighten it
❑ 5 Nm +135°
4 - Pipe connection
❑ With O-rings (supplied
with pipe connection)
❑ Renew after loosening
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 18 Nm
5 - High-pressure pipe
❑ Counterhold at pipe
connection when loos‐
ening
❑ Do not alter shape
❑ Screw in union nut by
hand until it makes con‐
tact
❑ 17 Nm
6 - Pipe connection
❑ With O-rings (supplied with pipe connection)
❑ Renew after loosening
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ 18 Nm
7 - Gas pressure regulator
❑ With high-pressure valve for gas mode - N372-
❑ Removing and installing ⇒ “6.2 Removing and installing gas pressure regulator”, page 195
8 - Sensor module - GX23-
❑ Removing and installing ⇒ “7.7 Removing and installing sensor module GX23 ”, page 203
❑ 20 Nm
9 - Bolt
❑ 8 Nm

10 - Bracket
11 - Bolt
❑ 2x
❑ 8 Nm
12 - Bolt
❑ 2x
❑ 8 Nm
13 - Bonded rubber bush
❑ Screw in by hand until contact is made
Natural gas low-pressure pipe - installation position

– Move natural gas low-pressure pipe into installation position.
• Angle -α- = max. 35°
6.2 Removing and installing gas pressure

regulator
6. Gas pressure regulator 195

Removing
system ⇒ page 2 .
cleanliness .
WARNING


WARNING


expansion tank.


– Carefully loosen union nuts -2- to release residual gas (coun‐
terhold at connection with a suitable tool).
– Unscrew union nut, move high-pressure pipe clear and detach
it slightly from gas pressure regulator.
Caution
Risk of gas leaks in gas pressure pipe due to improper han‐

dling.
♦ Do not attempt to bend gas pressure pipe to a different
shape

– Remove bolts -4- and detach gas pressure regulator.
Installing
ing battery .
6. Gas pressure regulator 197

WARNING

structed person.

WARNING


leaks .
Tightening torques

7 Senders and sensors

⇒ “7.1 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 199
⇒ “7.2 Removing and installing air mass meter G70 ”, page 200
⇒ “7.3 Removing and installing fuel pressure sender G247 ”, page
200
⇒ “7.4 Checking fuel pressure sender G247 ”, page 201
⇒ “7.5 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 201
⇒ “7.6 Removing and installing gas rail temperature and pressure
sensor GX21 ”, page 202
⇒ “7.7 Removing and installing sensor module GX23 ”,
page 203
7.1 Removing and installing intake air tem‐

perature sender - G42- / intake manifold
pressure sender - G71-
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Remov‐
ing and installing intake air temperature sender - G42- / intake
manifold pressure sender - G71- .
7. Senders and sensors 199

7.2 Removing and installing air mass meter

- G70-
Removing
– Release hose clip -3- and detach air pipe.
– Remove bolts -arrows- and detach air mass meter - G70-
-item 1-.
Installing
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power as the calculated in‐
jection quantities will be too low.
♦ Check air filter element and inside of air cleaner housing for
dirt; clean if necessary ⇒ Maintenance ; Booklet 830 ; Main‐
tenance work; Air cleaner: renewing filter element and clean‐
ing housing .
Tightening torques
charge air system
7.3 Removing and installing fuel pressure

sender - G247-
⇒ “7.3.1 Removing and installing fuel pressure sender G247 - ve‐
hicles with alternator”, page 200
hicles with starter-alternator”, page 201
7.3.1 Removing and installing fuel pressure

sender - G247- - vehicles with alternator
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Removing and installing fuel pressure sender - G247- .
Installing
Additional work:


ing battery .

sender - G247- - vehicles with starter-
alternator
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Remov‐
ing and installing fuel pressure sender - G247- .

sender - G247- - vehicles with natural
gas system
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Removing and installing fuel pressure sender - G247- .
Installing
Additional work:
7.4 Checking fuel pressure sender - G247-

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Checking
fuel pressure sender - G247- .
7.5 Removing and installing fuel pressure

sender for low pressure - G410-
⇒ “7.5.1 Removing and installing fuel pressure sender for low
pressure G410 - vehicles without natural gas system”,
page 201
⇒ “7.5.2 Removing and installing fuel pressure sender for low
pressure G410 - vehicles with natural gas system”, page 201

sender for low pressure - G410- - vehi‐
cles without natural gas system
stalling fuel pressure sender for low pressure - G410- .

sender for low pressure - G410- - vehi‐
cles with natural gas system

♦ Socket, 27 mm - T40218-
Removing
– Unscrew fuel pressure sender for low pressure - G410-
-item 2- using socket, 27 mm - T40218- .
Installing
Tightening torques
24 ; Injectors; Exploded view - fuel rail with injectors
7.6 Removing and installing gas rail temper‐

ature and pressure sensor - GX21-
Removing
system ⇒ page 2 .
cleanliness .
WARNING




– Unscrew gas rail temperature and pressure sensor - GX21-
-item 1-; to do so, counterhold at connection on gas rail with a
suitable tool.
Installing
WARNING

structed person.

WARNING


Tightening torques
♦ ⇒ “5.1 Exploded view - gas rail”, page 189
7.7 Removing and installing sensor module

- GX23-

♦ Socket, 27 mm - T40218-
Removing
system ⇒ page 2 .
cleanliness .
WARNING


– Unscrew sensor module - GX23- -2- from gas pressure regu‐
lator using socket, 27 mm - T40218- .

Installing
WARNING

structed person.

WARNING


leaks .
Tightening torques

8 High-pressure pump
⇒ “8.1 Exploded view - high-pressure pump”, page 206
⇒ “8.2 Removing and installing high-pressure pump”, page 208
8.1 Exploded view - high-pressure pump

⇒ “8.1.1 Exploded view - high-pressure pump, vehicles without
⇒ “8.1.2 Exploded view - high-pressure pump, vehicles with nat‐
8.1.1 Exploded view - high-pressure pump,

vehicles without natural gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump; Exploded
view - high-pressure pump .
8.1.2 Exploded view - high-pressure pump, vehicles with natural gas system
1 - Vacuum pump
❑ Exploded view ⇒ Brake
system; Rep. gr. 47 ;
Vacuum system; Explo‐
ded view - vacuum
pump
2 - Roller tappet
❑ May remain lodged in
vacuum pump when
high-pressure pump is
removed
3 - O-ring
❑ Notes on installation ⇒
Servicing 4-cylinder en‐
gine, 2.0 ltr. 4-valve
TFSI; Rep. gr. 24 ; High-
pressure pump; Explo‐
ded view - high-pres‐
sure pump
4 - Cooling flange
❑ For high-pressure pump
5 - O-ring
❑ Notes on installation ⇒
Servicing 4-cylinder en‐
gine, 2.0 ltr. 4-valve
TFSI; Rep. gr. 24 ; High-
pressure pump; Explo‐
ded view - high-pres‐
sure pump
6 - High-pressure pump
❑ Depending on version,
with integrated fuel me‐
tering valve - N290- or
fuel pressure regulating
valve - N276-
❑ Removing and installing ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pump

7 - Bolt
❑ Tighten in stages
♦ Screw in by hand until contact is made
♦ Tighten one turn alternately until flange of high-pressure pump makes contact with vacuum pump
♦ 8 Nm +90°
8 - Connection
9 - Fuel supply hose
❑ From fuel tank
10 - Spring-type clip
❑ Notes on installation ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Exploded view - high-pressure pump
11 - Bolt
❑ 9 Nm
12 - Fuel pressure sender - G247-
14 - Fuel supply hose
❑ From fuel tank
16 - Connection
❑ For fuel supply line
❑ Tightening torques and notes on installation ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep.
gr. 24 ; High-pressure pump; Exploded view - high-pressure pump
17 - High-pressure pipe
❑ To fuel rail
18 - Bolt
19 - Coolant hoses
8. High-pressure pump 207

8.2 Removing and installing high-pressure

pump
⇒ “8.2.1 Removing and installing high-pressure pump - vehicles
without particulate filter”, page 208
⇒ “8.2.2 Removing and installing high-pressure pump - vehicles
with particulate filter”, page 208
8.2.1 Removing and installing high-pressure

pump - vehicles without particulate filter
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump; Remov‐
ing and installing high-pressure pump .
8.2.2 Removing and installing high-pressure

pump - vehicles with particulate filter
Removing

sender 3 - G495- / exhaust gas temperature sender 4 - G648-
out of bracket and unplug.
sions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump;
Removing and installing high-pressure pump .
Installing
Additional work:
Tightening torques

9 Lambda probe
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe .
9. Lambda probe 209

10 Engine control unit

⇒ “10.1 Exploded view - engine control unit”, page 210
⇒ “10.2 Removing and installing engine/motor control unit J623 ”,
page 211
10.1 Exploded view - engine control unit

⇒ “10.1.1 Exploded view - engine control unit, vehicles without
⇒ “10.1.2 Exploded view - engine control unit, vehicles with nat‐
10.1.1 Exploded view - engine control unit, vehicles without natural gas system
1 - Bolt
❑ 9 Nm
2 - Mounting
❑ For engine control unit -
J623-
❑ Before renewal, perform
adaptions listed in Gui‐
ded Function “01 - Func‐
tions, engine mechan‐
ics” ⇒ Vehicle diagnos‐
tic tester.
⇒ page 211
4 - Bolt
❑ 9 Nm
5 - Suspension turret

10.1.2 Exploded view - engine control unit, vehicles with natural gas system
1 - Battery tray
2 - Mounting
❑ For engine control unit -
J623-
3 - Bolt
❑ 9 Nm
4 - Nut
❑ 9 Nm
5 - Clip
6 - Clip
❑ Before renewal, perform
adaptions listed in Gui‐
ded Function “01 - Func‐
tions, engine mechan‐
ics” ⇒ Vehicle diagnos‐
tic tester.
⇒ page 211
8 - Clip
10.2 Removing and installing engine/motor

control unit - J623-
Removing
Note
If engine control unit is renewed, run “01 - Replace control unit”

in Guided Functions mode of ⇒ Vehicle diagnostic tester.
10. Engine control unit 211


J623- -item 2-.

J623- -item 2-.
Installing
– If engine control unit - J623- was renewed, perform adaptions
listed in Guided Function “01 - Functions, engine mechanics”
⇒ Vehicle diagnostic tester.

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 213
⇒ “1.2 Removing and installing front exhaust pipe”, page 221
⇒ “1.3 Separating exhaust pipes/silencers”, page 222
⇒ “1.4 Removing and installing front silencers”, page 223
⇒ “1.5 Removing and installing silencers”, page 226
⇒ “1.6 Stress-free alignment of exhaust system”, page 228
⇒ “1.7 Checking exhaust system for leaks”, page 229
1.1 Exploded view - silencers

⇒ “1.1.1 Exploded view - silencers, front-wheel drive vehicles
without natural gas system”, page 213
⇒ page 216
⇒ “1.1.3 Exploded view - silencers, vehicles with four-wheel
drive”, page 219
1.1.1 Exploded view - silencers, front-wheel drive vehicles without natural gas
system
1. Exhaust pipes/silencers 213

1 - Rubber mounting
❑ Red-coloured mounting
must be renewed after it
has been pulled off
❑ Align exhaust system so
it is free of stress
⇒ page 228
2 - Bolt
❑ 23 Nm
3 - Retainer
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed separately
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
5 - Bolt
❑ 23 Nm
6 - Retainer
7 - Rubber mounting
❑ Red-coloured mounting
must be renewed after it
has been pulled off
⇒ page 228
8 - Front silencer
❑ With flexible joint
Caution
Risk of damage to flexi‐
ble joint.
Do
♦ not bend flexible joint
more than 10°.
Install
♦ flexible joint so that
it is not under tension.
Take
♦ care not to damage
wire mesh on flexible
joint.

⇒ “1.4.1 Removing and installing front silencer - vehicles without particulate filter”, page 223
❑ Align exhaust system so it is free of stress ⇒ page 228
9 - Gasket
214 Rep. gr.26 - Exhaust system

10 - Nut
❑ 23 Nm
11 - Mounting
❑ Different versions
❑ Red-coloured mounting must be renewed after it has been pulled off
❑ Check preload ⇒ page 228
12 - Bolt
❑ 23 Nm
13 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 228
❑ Tighten screw connections evenly to 23 Nm
14 - Rubber mounting
15 - Retainer
16 - Bolt
❑ 23 Nm
17 - Rear silencer
❑ Different versions available ⇒ Electronic parts catalogue
❑ Combined in one unit with centre silencer as original equipment. Can be renewed separately for repair
purposes
❑ Cutting point ⇒ page 222
18 - Clamp (rear)
Components of mountings for front silencer - vehicles without

particulate filter
1- Spacer sleeve
2- Compression spring
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Spacer sleeve

Installation position - front clamp

– Fit clamp in position shown.
• Angle -α- = approx. 20°
• Bolt connections facing towards right
• Nuts face downwards.
Installation position - rear clamp

• Bolted connections facing towards left
• Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
1.1.2 Exploded view - silencers, front-wheel drive vehicles with natural gas sys‐
tem

1 - Exhaust pipe
with rear silencer as
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
2 - Clamp (front)
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 228
⇒ page 218
❑ Tighten screw connec‐
tions evenly to 23 Nm
3 - Front exhaust pipe
Caution
ble joint.
Do
more than 10°.
Install
Take
joint.

4 - Gasket
5 - Nut
❑ 23 Nm
6 - Bolt
❑ 23 Nm
7 - Mounting
8 - Front silencer
⇒ “1.4.3 Removing and installing front silencer - vehicles with natural gas system”, page 226
9 - Bolt
❑ Tightening torques ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim

10 - Retainer
13 - Retainer
14 - Bolt
❑ Tightening torques ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim
15 - Nut
❑ 23 Nm
16 - Retainer
18 - Bolt
❑ 23 Nm
19 - Rear silencer
❑ Combined with front silencer as original equipment. Can be renewed separately for repair purposes
20 - Clamp (rear)
Installation position - front clamp

• Bolted connections facing towards left
• Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.

• Position clamp -1- so that it makes contact with retainer

-arrow-.
Installation position - rear clamp

♦ Bolted connections facing towards left
♦ Nuts face downwards.
♦ Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
1.1.3 Exploded view - silencers, vehicles with four-wheel drive

1 - Centre silencer
with rear silencers as
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
2 - Rubber mounting
⇒ page 228
3 - Bolt
❑ 23 Nm
4 - Retainer
5 - Front silencer
Caution
ble joint.
Do
more than 10°.
Install
Take
joint.

⇒ “1.4.1 Removing and installing front silencer - vehicles without particulate filter”, page 223
6 - Gasket
7 - Nut
❑ 23 Nm
8 - Bolt
❑ 23 Nm
9 - Mounting
10 - Clamp (front)
11 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed separately for repair
purposes


12 - Mounting
13 - Bolt
❑ 23 Nm
14 - Clamp (rear)
15 - Retainer
16 - Bolt
❑ 23 Nm
1.2 Removing and installing front exhaust

pipe
Removing
– Remove nuts -1- (accessible from above) for front exhaust
pipe.
noise insulation .
– Remove bolts -arrows- for front exhaust pipe.

– Loosen clamp -arrows-.
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.
– Carefully detach front exhaust pipe from front silencer and re‐
move.
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre silencer/exhaust pipe or rear si‐
lencer separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipes at right angle at notch -arrow- using
chain pipe cutter - VAS 6254- .

– Position centre of clamps -arrows- over cutting location.

– Fit clamps ⇒ page 216 .
Tightening torques
1.4 Removing and installing front silencers

⇒ “1.4.1 Removing and installing front silencer - vehicles without
⇒ “1.4.2 Removing and installing front silencer - vehicles with
⇒ “1.4.3 Removing and installing front silencer - vehicles with
1.4.1 Removing and installing front silencer -

vehicles without particulate filter
Removing
noise insulation .

Caution


Installing
Note
Renew gaskets, seals and self-locking nuts after removal.

Tightening torques

vehicles with particulate filter
Removing
– Unscrew nuts -arrows- for front silencer.

– Unscrew bolts -arrows- for front silencer (shown on right side).
Caution


Installing
Note
Renew gaskets, seals and self-locking nuts after removal.

Tightening torques


vehicles with natural gas system
Removing
– Remove tunnel cross-piece ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody
struts .
WARNING
Risk of accident caused by weight of silencer.

♦ A second mechanic is required for removal of the front
silencer.
– Loosen clamp -4-.

– Loosen clamp -2- and push to rear.
– Disengage mounting -1- at exhaust system.
– Disconnect front silencer -3- from front exhaust pipe and re‐
move.
Installing
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts
1.5 Removing and installing silencers

⇒ “1.5.1 Removing and installing silencers - vehicles without nat‐
⇒ “1.5.2 Removing and installing silencers - vehicles with natural
gas system”, page 228
1.5.1 Removing and installing silencers - ve‐

hicles without natural gas system
Removing
– Depending on country/equipment version: Remove diagonal
struts (left and right) ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody struts .
– Remove tunnel cross-piece ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody
struts .

Caution

than 10°.
– Lower front silencer slightly and detach clamp.

– Tie up front silencer.
Vehicles with front-wheel drive:
WARNING
Risk of accident caused by weight of silencers.

♦ A second mechanic is required for removal of the rear si‐
lencer.
– Unscrew bolts -1, 3- and remove silencer -2-.
Vehicles with four-wheel drive:
WARNING

lencer.
– Disengage mounting -2- at exhaust system.

– Unscrew bolts -3- and remove silencer -1-.
Installing
Tightening torques
trim; Exploded view - underbody trim

1.5.2 Removing and installing silencers - ve‐

hicles with natural gas system
Removing rear silencer without cutting point
– Remove diagonal struts (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody struts .
WARNING

lencers.
– Loosen clamp -1- and push to rear.

– Unscrew bolts -arrows- and remove silencer -2-.
– Screw in bolts again until contact is made.
Removing rear silencer with cutting point

– Loosen clamp -3-.
– Unscrew bolt -2-, slide clamp towards front and detach silenc‐
er -1-.
– Screw in bolts again until contact is made.
Installing
Tightening torques
1.6 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.

– Slacken front clamp -arrows-.
– Push exhaust system towards front of vehicle -arrow- so that

mounting -1- for exhaust pipe is preloaded by -a- = 6 ... 10 mm.
– Position clamp at front ⇒ page 216 and tighten bolted con‐
nections evenly.
A4/A5 before product upgrade

– Check clearance between tailpipes and bumper on both sides:
• Dimension -x- (left-side) = dimension -x- (right-side)
Tightening torques
1.7 Checking exhaust system for leaks

2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;
Checking exhaust system for leaks .

2 Emission control system

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission
control system .

28 – Ignition system
1 Ignition system
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system .
1. Ignition system 231

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Service

Service Department. Technical Information

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Copyright © 2019 Audi AG, Ingolstadt D4B80595B99

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Risk of explosion due to flammable natural gas - risk of death!

Risk of injury due to high pressure

2.2 Safety precautions for all vehicles

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

1.1.1 Removing engine - vehicles without par‐

♦ Lifting tackle - 2024A-

4 Rep. gr.10 - Removing and installing engine

♦ Gearbox support - 3147-

♦ Lambda probe open ring spanner set - 3337-

♦ Ring spanner insert AF 16 - V.A.G 1332/14-

♦ Workshop hoist - VAS 6100-

1. Removing and installing engine 5

♦ Engine bung set - VAS 6122-

♦ Coolant collecting system - VAS 5014- or drip tray for work‐

♦ Hose clip pliers - VAS 6362-

♦ Adapter - VAS 6948-

6 Rep. gr.10 - Removing and installing engine

♦ Locking pin - T10060A-

♦ -T40093/6- from engine support supplementary set - T40093-

♦ Ratchet wrench (21 mm) - T40263-

1. Removing and installing engine 7

♦ The engine is removed upwards without gearbox.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

The cooling system is under pressure when the power unit is

– Release fastener -arrow- and open filler cap -1- on coolant

8 Rep. gr.10 - Removing and installing engine

– On relevant equipment version: Unplug electrical connector

All vehicles (continued):

– Unplug electrical connector -2- for air mass meter - G70- .

– Release catch -arrow B- and open electronics box -1-

1. Removing and installing engine 9

– Remove nuts -1- (accessible from above) for front silencer.

– Unplug electrical connector -1- for charge pressure sender -

– Place collector tank from coolant collecting system -VAS

10 Rep. gr.10 - Removing and installing engine

Vehicles without belt-driven starter-alternator:

Running a used poly V-belt in the opposite direction could

– To slacken poly V-belt turn tensioner in direction of -arrow-.

Vehicles with belt-driven starter-alternator:

Running a used poly V-belt in the opposite direction could

– To slacken poly V-belt turn tensioner in direction of -arrow-.

1. Removing and installing engine 11

– Detach electrical connector -2- from bracket and unplug.

– Remove nut -arrow- and move earth wire clear.