eSelf Study Program 920143

The Audi 2.0L Third Generation TDI Engine

2

Audi of America, LLC
Service Training
Created in the U.S.A.
Created 4/2014
Course Number 920143
©2014 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.

This eSSP contains video links which you
can use to access interactive media.

Note
This eSelf Study Program provides 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.

Revision 1: 5/2014
3

Reference

Contents
Introduction......................................................................................6
Brief technical description ................................................................................................................................... 7
Specifications of 2.0l TDI engine ......................................................................................................................... 9

Engine mechanicals...........................................................................10
Cylinder block ........................................................................................................................................................
Crankshaft assembly ............................................................................................................................................
Balancer shafts .....................................................................................................................................................
Toothed belt drive .................................................................................................................................................
Auxiliary component drive ...................................................................................................................................
Cylinder Head.........................................................................................................................................................
Layout of the valves ..............................................................................................................................................
Cylinder head coolant jacket ................................................................................................................................

10
11
12
13
14
15
16
17

Variable camshaft timing..................................................................19
Introduction .......................................................................................................................................................... 19
Operating ranges .................................................................................................................................................. 21

Positive crankcase ventilation............................................................22
Oil supply...........................................................................................23
Oil circuit ............................................................................................................................................................... 23
Oil pump with integral vacuum pump ................................................................................................................ 24
Oil filter module .................................................................................................................................................... 28

Cooling system..................................................................................30
Thermal management .........................................................................................................................................
Switchable coolant pump ....................................................................................................................................
System overview ...................................................................................................................................................
Coolant thermostat ..............................................................................................................................................
Coolant expansion tank with silicate repository ................................................................................................

30
30
32
37
38

Fuel System.......................................................................................39
Fuel injectors .........................................................................................................................................................
Injector in rest position ........................................................................................................................................
Start of injection ...................................................................................................................................................
Pre-heating the fuel filter ....................................................................................................................................
Pulsation damper .................................................................................................................................................

40
41
42
43
44

Engine management system.............................................................45
System overview ...................................................................................................................................................
Glow plug system .................................................................................................................................................
Function .................................................................................................................................................................
Air regulation overview ........................................................................................................................................
Charge pressure control .......................................................................................................................................
Charge air cooler ...................................................................................................................................................

45
47
48
49
51
53

Exhaust system.................................................................................55
Longitudinally mounted engines ......................................................................................................................... 55
Transversely mounted engines ............................................................................................................................ 55

Exhaust gas treatment......................................................................57
Exhaust emission standards ................................................................................................................................ 57
Exhaust Door Control Unit J883 .......................................................................................................................... 62
SCR-System ........................................................................................................................................................... 64

Special tools and workshop equipment.............................................67
Knowledge Assessment....................................................................69

4

608_001

5

Introduction
A new family of diesel engines has been developed with the
designation EA288. EA is for Entwicklungsauftrag which
means “development order.” It is based on the existing
EA189 engine family.
Audi engineers have translated this development to the
Modular Diesel Platform (MDP) so successive platforms in
the mid-range, compact and subcompact classes can be
supplied with identical or adapted engine modules.

The modular design principle has been applied both to the
core assemblies (basic engine assembly, cylinder head and
valve train) and to the ancillary components (close-coupled
exhaust gas treatment system and intake manifold with
integrated charge air cooler). Numerous sub-assemblies
have already been redesigned and re-developed for the new
4-cylinder diesel engines in the EA288 family.

1

4

2

5

3

6

7

8

9

10

514_104a

Core assemblies

Ancillary components

1 Camshaft housing

7 Exhaust manifold module with turbocharger

2 Cylinder head

8 Intake manifold with water-cooled charge air cooler

3 Cylinder block

9 Exhaust purification module

4 Switchable coolant pump

10 Exhaust gas recirculation module

5 Oil/vacuum pump
6 Timing drive and drive for auxiliary units

EA288 Engine

6

Brief technical description
2.0l 4-cylinder TDI for the North American Region

Cylinder block with integrated balancer shafts

608_008

Oxidizing catalytic converter and diesel particulate filter (shown here in a transverse engine configuration.)

608_049

Cylinder head with variable valve timing

608_021
7

Oil pump with integrated vacuum pump

608_017

Switchable coolant pump

608_018

Intake manifold with integrated charge air cooler

608_009

608_019
8

Specifications of 2.0l TDI engine
Torque-power curve

500 Nm (369 lb ft) 180 kW (241 hp)

Engine with engine code CRUA (USA)
450 Nm (332 lb ft) 160 kW (214 hp)

  Power output in kW (hp)
  Torque in Nm (lb ft)

400 Nm (295 lb ft) 140 kW (188 hp)

350 Nm (258 lb ft) 120 kW (161 hp)

300 Nm (221 lb ft) 100 kW (134 hp)

250 Nm (184 lb ft) 80 kW (107 hp)

200 Nm (148 lb ft) 60 kW (80 hp)

150 Nm (111 lb ft) 40 kW (54 hp)

100 Nm (74 lb ft) 20 kW (27 hp)

625_082

1000

2000

3000
Engine speed [rpm]

Engine code

9

5000
625_023

CRUA

Type
Displacement in cm

4000

Four-cylinder in-line engine
3

1968

Stroke in mm

95.5

Bore in mm

81.0

Cylinder spacing in mm

88.0

Number of valves per cylinder

4

Firing order

1–3–4–2

Compression ratio

16.2 : 1

Power output at rpm

110 at 3500 – 4000 (147.5 hp at 3500 - 4000)

Torque at rpm

320 at 1750 – 3000 (236.0 lb ft at 1750 - 3000)

Fuel

ULSD (Ultra Low Sulfur Diesel) with a sulfur content of 15 ppm or less; must meet
ASTM D975 Grade 2 S15 specifications

Engine management system

Bosch EDC 17

Maximum injection pressure in bar

2000

Emission standard

BIN 5 – Tier 2

CO2 emission in g/km

106

Engine mechanicals
Cylinder block
The cylinder block is made from an alloy of cast iron and
nodular graphite (GG GJL 250).
The threads for the cylinder head bolts have been relocated
to a position lower in the block.
The net effect of lowering the threads is to ensure an even
distribution of forces produced by the engine throughout
the cylinder block. It also helps ensure an equal pressure
distribution over the entire surface area of the cylinder
head gasket.
The cylinders are surfaced honed after a torque plate has
been bolted to the cylinder block. The use of the plate

ensures that there will be no bore distortion in the cylinder block once the cylinder head has been mounted and
tightened to the proper torque specification. This also
reduces the stress on the piston rings which in turn
reduces friction. This process also leads to less blow-by
gas and oil consumption.

The cylinder block has the following technical features:
•
•
•
•

Integrated balancer shafts above the crankshaft
Short-path water jacket for rapid component heating
Optimal cooling of the webs between the cylinders
Optimized oil and water circuits to facilitate ITM

Cylinder block

Balancer shaft

Baffle plate/oil windage tray

Oil pan

608_016
10

Crankshaft assembly
The trapezoidal connecting rods are cracked at the lower
end as on previous engines.

A forged crankshaft with five bearings is used in the EA288
engine. To reduce weight, the crankshaft only has four
counterweights to counteract the rotating forces of inertia.
The load on the crankshaft bearings is also reduced by this
measure.

The pistons have no valve pockets. This design of the piston
crown reduces the dead space and improves the swirl formation of the intake air in the cylinder.

Noise emissions, which may be caused by the engine’s
inherent movement and vibrations, have also been reduced.
The toothed belt sprocket for the camshaft drive belt and
the sprocket for the oil pump drive have been press-fit to
the crankshaft.

Oil pump chain sprocket

The piston ring zones are cooled by engine oil via spray jets
fed from a piston cooling gallery in the cylinder block. (See
page 23).

Balancer shaft 1

Balancer shaft drive sprocket

Camshaft belt
sprocket

Balancer shaft 2

608_015

11

Balancer shafts
The movement of the pistons and connecting rods as well
as the reciprocal movement of the crankshaft produce
forces that cause vibrations. To counteract these vibrations,
two balancer shafts rotate in opposite directions at twice
the engine speed.

The shafts and idler gear are fixed in position radially and
axially by roller bearings. The bearings are lubricated with
oil spray from the cylinder block. Lubricating the roller
bearings in this manner reduces the drag effect at low
engine temperatures and high engine speeds.

The balancer shafts are driven by a helical-cut gear mounted
on the crankshaft. The direction of Balancer shaft 1 is
reversed through the use of an idler gear.

Roller bearing

Balancer shaft 2

Roller bearing

Balancer shaft drive sprocket

Balancer shaft 1

Crankshaft

Idler gear
for direction reversal
608_034

12

Toothed belt drive
The camshafts, high pressure fuel pump and engine coolant
pump are all driven by the crankshaft via a toothed belt.
The toothed belt is tensioned by an spring operated automatic belt tensioner. Two idler rollers ensure better
meshing of the toothed belt to the drive sprockets.

Camshaft sprocket

Idler roller

Automatic tensioning pulley

Crankshaft

Idler roller

Coolant pump

High pressure
fuel pump
608_023

13

Auxiliary component drive
Two auxiliary components - the alternator and the air
conditioning compressor - are driven by the crankshaft with
a poly V-belt. The pulley on the crankshaft also serves as a
vibration damper.
The poly V-belt is tensioned by a spring-loaded belt tensioner.

Automatic tensioning pulley

Alternator

Crankshaft
vibration damper

A/C compressor
608_035

14

Cylinder Head
The cylinder head of the engine is a cross-flow design made
of aluminum alloy. The valves are operated by two overhead camshafts integrated into a separate housing module.
One camshaft is driven by the toothed drive belt. The
second camshaft is driven by a spur gear attached to the
first.
Because of the valve layout for the cylinders, each camshaft
controls both intake and exhaust valves.

Cylinder Head

Camshaft Housing

608_022

Camshaft housing
The camshafts are integrated into a closed retaining frame
using a thermal joining process and cannot be separated
from the frame. This design ensures a rigid support for the
camshaft bearings while keeping weight low.

The sender wheel for Camshaft Position Sensor G40 is
located on one camshaft. It provides the ECM the current
position of both camshafts.

To reduce friction, the first bearing (which is subjected to
the highest load forces of the toothed drive belt) is a needle
bearing.

Hall Sensor G40
Camshaft adjuster

Retaining frame with camshafts

608_020

Note

The camshafts can only be replaced together with the housing if repairs are necessary.

15

Layout of the valves
The layout of the valves in the cylinder has been changed
when compared to the previous generation diesel engine.
The position of the valves (sometimes referred to as the
‘valve star’) has been rotated to the longitudinal axis of
the engine. This means that the intake and exhaust ports
for each cylinder are positioned one behind the other in
the direction of flow.

It also means that each camshaft actuates one intake
and one exhaust valve per cylinder. The valve layout was
re-designed to allow maximum air delivery and enhance
the swirl effect. It also helps ensure compliance to
current and future exhaust emission standards.

Intake air

First exhaust valve,
cylinder 2

First inlet valve,
cylinder 2

Second exhaust valve,
cylinder 2

Second inlet valve,
cylinder 2
Cylinder 1

Intake side
Exhaust gas

Exhaust side

608_036

608_036

16

Cylinder head coolant jacket
The coolant jacket in the cylinder head is divided into upper
and lower sections. The lower coolant jacket core has a
larger volume, ensuring there is a high level of heat dissipation in the part of the cylinder head close to the combustion chamber. The two cores in the cast part of the cylinder
head are separate.

When the engine is cold, the coolant is channelled out of