AUDI Self Study Programme 994606AG The Audi 1.8L and 2.0L Third Generation EA888 Engines.pdf

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eSelf-Study Program 994606AG
The Audi 1.8L and 2.0L Third Generation
EA888 Engines
1
Audi of America, LLC
Service Training
Created in the U.S.A.
Created 11/2013
Course Number 920243
©2013 Audi of America, LLC
All rights reserved. Information contained in this manual is based on
the latest information available at the time of printing and is subject to
the copyright and other intellectual property rights of Audi of America,
LLC., its affiliated companies and its licensors. All rights are reserved
to make changes at any time without notice. No part of this document
may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording
or otherwise, nor may these materials be modified or reposted to other
sites without the prior expressed written permission of the publisher.
All requests for permission to copy and redistribute information should
be referred to Audi of America, LLC.
Always check Technical Bulletins and the latest electronic service repair
literature for information that may supersede any information included
in this booklet.
Revision 2: 12/2013
2
Contents
Introduction .........................................................................................5
Development goals ...................................................................................................................................................... 6
Brief technical description .......................................................................................................................................... 7
Technical features ........................................................................................................................................................ 8
Engine mechanicals ........................................................................... 10
Overview .....................................................................................................................................................................10
Cylinder block .............................................................................................................................................................10
Oil pan .........................................................................................................................................................................11
Crankshaft assembly .................................................................................................................................................12
Chain drive ..................................................................................................................................................................14
Balance shafts ............................................................................................................................................................15
Auxiliaries mounting bracket ....................................................................................................................................16
Cylinder head .............................................................................................................................................................18
Integral exhaust manifold ........................................................................................................................................21
Positive crankcase ventilation ..................................................................................................................................23
Oil supply ........................................................................................... 28
System overview ........................................................................................................................................................28
Oil supply ....................................................................................................................................................................30
Oil filler cap ................................................................................................................................................................32
Switchable piston cooling jets ..................................................................................................................................32
Cooling system .................................................................................. 34
System overview ........................................................................................................................................................34
Innovative Thermal Management (ITM) ..................................................................................................................36
Air supply and charging ..................................................................... 49
System overview ........................................................................................................................................................49
Air routing system for transversely mounted engines ...........................................................................................50
Air routing system for longitudinal mounted engines ...........................................................................................51
Intake manifold .........................................................................................................................................................52
Turbocharger ..............................................................................................................................................................53
Fuel system ....................................................................................... 57
System overview ........................................................................................................................................................57
Mixture formation / dual injection system ..............................................................................................................58
Operating modes .......................................................................................................................................................59
Engine management system ............................................................. 62
System overview example – 1.8l TFSI engine .........................................................................................................62
Differences between 1.8L longitudinally and transversely mounted engines .....................................................64
Differences between components in the engines with 1.8 l and 2.0 l displacement ..........................................65
Component differences for the 2015 Audi S3 ........................................................................................................66
Differences between the exhaust turbochargers ...................................................................................................67
Differences between combustion methods ............................................................................................................68
Special tools ...................................................................................... 69
Self Study Programs .......................................................................... 70
Knowledge Assessment .................................................................... 71
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This eSSP contains video links which you
can use to access interactive media.
This eSelf Study Program teaches a basic knowledge of the design and functions of new models,
new automotive components or technologies.
It is not a Repair Manual!
All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.
Note
Reference
4
Introduction
The launch of the new 1.8L and 2.0L TFSI engines marks the
beginning for the third generation of the successful EA888
four cylinder engine family from Audi. The motives for this
development are increasingly stringent exhaust emission
standards, better fuel economy and reduced CO
2
emissions.
To achieve these goals, the engines have been completely
revised.
This “global engine” is manufactured at Audi’s Hungarian
plant in Györ; in Silao, Mexico; Shanghai and Dallan China.
In the future it will also be produced in Changchun. Like the
second generation versions of this engine, it is available in
both 1.8L and 2.0L displacements. It is used for a variety of
vehicle platforms and Group brands and is available in a wide
range of power ratings.
Another design requirement was that the engines be suit-
able for use in all markets, including those where low grade
fuel is prevalent.
Please note:
Some illustrations of the 1.8L engine in this eSelf-Study
Program are for the world-wide market. With the North
American introduction of the third generation EA888
engines, the 1.8L engine will not have a continuously adjust-
able exhaust camshaft nor AVS.
Learning objectives of this eSelf Study Program:
This eSelf-Study Program introduces you to the technology
of the third generation of EA888 4 cylinder engines. Upon
completing this eSelf-Study Program, you will be able to
answer the following questions:
•
•
•
What are the key technical modifications behind the
development of the EA888 engine family?
How do the innovative, new technologies work?
What changes do the 1.8L and 2.0L engines bring to
customer service?
606_001
Reference
For a detailed technical description of the first generation engine, please refer to eSelf-Study Program 921703,
The Audi 2.0 Liter Chain-driven TFSI Engine.
Reference
To find more about the modifications to the first and second generation engines, please refer to eSelf-Study
Program 922903,
The 2.0L 4V TFSI Engine with AVS.
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