System overview example – 1.8l TFSI engine
Sensors
Throttle Valve Control Module J338
EPC Throttle Drive Angle Sensors 1 & 2 G187, G188
Brake Light Switch F
Clutch Position Sensor G476
Clutch Pedal Switch F36
Clutch Pedal Starter Interlock Switch F194
Accelerator Pedal Position Sensor G79
Accelerator Pedal Position Sensor 2 G185
Knock Sensor 1 G61
Low Fuel Pressure Sensor G410

Hall Sensor G40
Hall Sensor 3 G300
Engine Coolant Temperature Sensor G62

Engine Coolant Temperature Sensor on Radiator Outlet G83

Engine Speed Sensor G28

Oil Level Thermal Sensor G266

Intake Manifold Runner Position Switch G336

Intake Air Temperature Sensor G42
Manifold Absolute Pressure Sensor G71

Fuel Pressure Sensor G247

Charge Air Pressure Sensor G31

Gear Recognition Sensor G604

Brake Booster Pressure Sensor G294

Heated Oxygen Sensor G39
Oxygen Sensor after Three Way Catalytic Converter G130
Oil Pressure Switch F22
Reduced Oil Pressure Switch F378
Oil Pressure Switch, Level 3 F447
Charge Pressure Actuator Position Sensor G581
Fuel Level Sensor G
Fuel Level Sensor 2, G169
Auxiliary signals:
−− Cruise control system
−− Speed signal
−− Start request to engine control module (keyless start 1 + 2)
−− Terminal 50
−− Crash signal from airbag control Module
62

Engine Control Module
J623

Actuators
Piston Cooling Nozzle Control Valve N522

Ignition Coils 1 - 4 with Output Stage
N70, N127, N291, N292

EPC Throttle Drive G186

Injectors 2, cylinders 1 – 4 N532 – N535

Injector, cylinders 1 – 4 N30 – N33

Transmission Coolant Valve N488

Turbocharger Recirculation Valve N249

Intake Manifold Runner Control Valve N316

Coolant Recirculation Pump V50

Camshaft Adjustment Valve 1 N205
Exhaust Camshaft Adjustment Valve 1 N318
(N318 only on 2.0L engines)
Fuel Metering Valve N290

Oil Pressure Regulation Valve N428

Cam Adjustment Actuators 1 - 8, F366, F373
(only on 2.0L engines)

Carbon Canister Purge Regulator Valve N80

Engine Temperature Control Actuator N493
Oxygen Sensor Heater Z19
Heater for Oxygen Sensor 1 after Catalytic Converter Z29

Charge Pressure Actuator V465

Left Electro-hydraulic Engine Mount Solenoid Valve N144
Right Electro-hydraulic Engine Mount Solenoid Valve N145

Fuel Pump Control Module J538
Transfer Fuel Pump G6

Coolant Fan Control Module J293
Coolant Fan V7
Coolant Fan 2 V177
Auxiliary signals:
−− Dual clutch Mechatronic Module / engine speed
−− ABS/ESP Control Module
−− A/C compressor
−− Starter control Module
606_076
63

Differences between 1.8L longitudinally and transversely mounted
engines
The following components have been adapted:

•
•
•
•
•

Oil pan top section
Honeycomb insert
Oil pump intake line
Oil pan
Exhaust turbocharger

Animation showing the differences
between the longitudinally and
transversely mounted engines using
the 1.8l TFSI engine as an example.

The top and bottom sections of the oil pan, the honeycomb
insert and the oil pump intake line have been modified so
that the initial oil fill is the same as before 5.7 qt (5.4L) and
that the oil system meets all the essential functional criteria, e.g. oil pressure, oil sludging, longitudinal and lateral
dynamics, uphill and downhill driving.

1.8l TFSI engine, transversely mounted

Turbocharger

Oil pan top section

Honeycomb insert

Oil pan
Oil pump intake line
606_071

64

Differences between components in the engines with 1.8 l and 2.0 l
displacement
Different parts:

•
•
•
•
•

Cylinder block (main bearing diameter 2.04 in [52 mm])
Crankshaft (stroke 3.62 in [92.8 mm])
Connecting rod with adapted inside micrometer
Main bearings 2.04 in ([52 mm], two-component
bearings are used throughout the entire kit)
Balancer shafts

•
•
•
•
•

Exhaust camshaft (valve lift 10 mm, adapted valve
timing)
Exhaust valves (hollow, bimetallic)
High pressure injectors (higher flow rate)
Intake manifold with integral drumble flap
Exhaust turbocharger

Animation showing the differences
between 1.8 l and 2.0 l displacements using the longitudinally
mounted engine as an example.

2.0l TFSI engine, transversely mounted

Exhaust camshaft
and valves

Intake manifold with
integral tumble flap

Turbocharger

FSI injectors

Balance shafts

Crankshaft and
con-rod
Cylinder block

606_072

65

Component differences for the 2015 Audi S3
The following parts have been adapted:

•
•
•
•
•
•

Cylinder head (made from a different alloy compared to
other engines in this module because of higher thermal
stress)
Exhaust valves (hollow, higher Ni content, nitrided)
Exhaust valve seat rings (improved temperature stability
and wear resistance)
Exhaust camshaft (adapted valve timings)
Compression ratio 9.3 : 1
Piston cooling jets (higher flow rate)

•
•
•
•
•

High pressure injectors (even higher flow rate)
Exhaust turbocharger
Charge pressures of up of 17.4 psi (1.2 bar)
High performance main radiator with 1 – 2 auxiliary
radiators (depending on country specifications)
Additional acoustic modifications have been made
in order to achieve a sporty sound - use of a sound actuator (for the occupant cell) and active exhaust flaps in the
exhaust system

Animation showing the 2015 Audi S3.

2.0l TFSI engine in Audi S3 ’13

Cylinder head
Exhaust camshaft, valves
and valve seat rings

FSI injectors

Pistons

Turbocharger
Piston cooling jets

606_073

Animation showing the different
components of the 2015 S3 engine.

66

Differences between the exhaust turbochargers
Even larger compressor and turbine wheels and specially
adapted housing components are used for the 2015 Audi S3.
Different materials are used for the turbine housing and the
turbine wheel so they are able to handle the high exhaust
gas mass flow rates.

A

B

C

A special feature of the Audi S3 turbocharger is the use of
"abradeable seal" technology (ICSI GmbH) in the compressor.
A self-adaptive plastic insert provides a much smaller gap
between the compressor wheel and housing. This increases
the efficiency of the compressor unit by up to 2%.

D

F

E

606_074

G
1.8 l MLB

B

1
C

1.8 l MQB

B

2

2.0 l MLB

B

3

C

1

D 1

2

E

F

1

F

2

1

E

2

F

3

E

3

F

4

D 2
2.0 l S3

B

4

C

3

A

G
606_078

Key:
A

Electrical diverter valve

E

Turbine wheel

B

Compressor housing

F

Turbine housing

C

Compressor wheel

G

Wastegate system

D

Bearing

MQB = transversely mounted engine
MLB = longitudinally mounted engine

67

Differences between combustion methods
1.8 l

2.0 l

2.0 l S3

High pressure injector flow rate

15 cm3/s

17.5 cm3/s

20 cm3/s

Intake ports

Tumble duct

Tumble duct

Tumble duct

Flap system

Tumble

Drumble

Drumble

Compression ratio

9.6 : 1

9.6 : 1

9.3 : 1

Intake camshaft adjuster

yes

yes

yes

Exhaust camshaft adjuster

no

yes

yes

Exhaust - Audi valvelift system (AVS)

no

yes

yes

Integral exhaust manifold

yes

yes

yes

Drumble flap
Depending on displacement, differing degrees of charge
motion occur when the intake flap is closed. To achieve the
same results, it would be necessary to use different intake
manifolds for the different displacements. To eliminate this
problem, different swirl flaps are used.

Drumble flaps are installed on the 2.0L versions of the third
generation EA888 engines.
In this design, the tumble duct is closed asymmetrically to
induce a combined swirling and tumbling flow motion in the
air/fuel charge.

606_075

Tumble flap in
1.8l TFSI engines
68

Drumble flap in
2.0l TFSI engines

Special tools
T10133/16 A Removal tool

T10133/18 Sleeve

606_048

606_049

For removing the high pressure injectors
Special tool T10133/16 A replaces the previous removal tool (T10133/16)

For removing the high pressure injectors

T40243 Lever

T40267 Locking tool

606_050

606_051

For inserting the crankshaft tensioner

For locking the clamping element

T40274 Puller hook

T40270 Socket insert XZN 12

606_054

606_052

For removing the crankshaft seal

For removing and installing the engine/ transmission mounts

T40271 Camshaft clamp

T40290 Setting gauge

606_053

For locking the drive chain sprockets

606_081

For locking the wastegate during adjustment work on the charge
pressure actuator of the exhaust turbocharger
69

Self Study Programs
To find out more about the technology of the EA888 engine family, refer to the following Self Study Programs.

eSelf-Study Program 921103,
The Audi 3.0L V6 Engine.

70

eSelf-Study Program 921703,
The Audi 2.0 Liter Chain-driven
TFSI Engine.

eSelf-Study Program 922903,
The 2.0L 4V TFSI Engine with
AVS.

Knowledge Assessment
An On-Line Knowledge Assessment (exam) is Available for this eSelf-Study Program.
The Knowledge Assessment is required for Certification.
You can find this Knowledge Assessment at:
www.accessaudi.com
From the accessaudi.com Homepage:

•
•
•

Click on the “ACADEMY” tab
Click on the “Academy site” link
Click on the Course Catalog Search and select “920243 - The Audi 1.8L and 2.0L Third Generation EA888 Engines”

Please submit any questions or inquiries via the Academy CRC Online Support Form
which is located under the “Support” tab or the “Contact Us” tab of the Academy CRC.

Thank you for reading this eSelf-Study Program and taking the assessment.

71

920243
All rights reserved.
Technical specifications are
subject to change without notice.
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2200 Ferdinand Porsche Drive
Herndon, VA 20171
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