2.0L - Engine Mechanical - AEG, AVH, AZG, BBW, BEV (A4 Platform)

• 00 General, Technical data
  • Technical data
    • Engine number
    • Engine data
• 10 Engine - Assembly
  • Engine, removing and installing
    • Engine, removing and installing
    • Engine, removing
    • Engine, attaching to assembly stand
    • Engine, installing
    • Engine and transmission mountings, aligning
    • Tightening torques
    • Assembly mounting
    • Additional information and assembly work on models with an air conditioning system
• 13 Engine - Crankshaft, Cylinder block
  • Engine, disassembling and assembling
    • Assembly overview
      • Notes
      • Part I
      • Part II
    • Poly V-belt, removing and installing
  • Sealing flanges and flywheel/drive plate, removing and installing
    • Sealing flanges and flywheel/drive plate, removing and installing
      • Notes
      • Identifying PTFE Seals - Teflon & Coil Spring Type
      • Identifying Intermediate Plate, Sealing Flange And Dowel Sleeves
    • Crankshaft oil seal - belt pulley end, replacing
    • Front sealing flange, removing and installing
    • Drive plate, removing and installing
  • Crankshaft, removing and installing
    • Crankshaft, removing and installing
      • Notes
      • Upper crankshaft bearing identification (gradual introduction)
    • Color markings
    • Crankshaft dimensions
  • Piston and connecting rod, disassembling and assembling
    • Piston and connecting rod, disassembling and assembling
    • Assembly overview
      • Conventional connecting rod
      • Industrially cracked connecting rod
      • Checking piston ring gap
      • Checking ring to groove clearance
      • Checking piston
      • Installation position of bearing shells
      • Checking cylinder bores
    • Piston and cylinder dimensions
• 15 Engine - Cylinder head, Valvetrain
  • Cylinder head, removing and installing
    • Cylinder head, removing and installing
      • Overview
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
    • Assembly overview
      • Notes
      • Engine codes AEG, AVH, AZG
      • Engine codes AEG, AVH, AZG with aluminum plate cylinder head gasket
      • Engine code BBW
      • Engine code BEV
      • Checking cylinder head for distortion
    • Toothed belts, removing, installing and tensioning
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
    • Semi-automatic toothed belt tensioning roller, checking
    • Compression pressures, checking
  • Valve gear, servicing
    • Valve gear, servicing
    • Assembly overview
      • Notes
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
      • Reworking cylinder head sealing surface
      • Checking camshaft axial clearance
      • Installed position of camshaft bearing caps
      • Valve dimensions
    • Valve seats, reworking
      • Notes
      • The maximum permissible reworking dimension is calculated as follows:
      • Reworking intake valve seat
      • Reworking exhaust valve seat
    • Camshaft oil seal, replacing
    • Camshaft, removing and installing
      • Notes
      • Engine codes AEG, AVH AZG, BEV
      • Engine code BBW
    • Hydraulic lifters, checking
    • Valve guides, checking
    • Valve guides, replacing
    • Valve stem seals, replacing
• 17 Engine - Lubrication
  • Lubrication system components, removing and installing
    • Lubrication system components, removing and installing
    • Engine codes AEG, AVH, AZG, BEV, assembly overview
    • Engine code BBW, assembly overview
      • Notes
      • Dipstick marks
    • Oil filter housing, disassembling and assembling
    • Oil pan, removing and installing
    • Oil pump, removing and installing
    • Oil pressure and oil pressure switch, checking
• 19 Engine - Cooling system
  • Cooling system components, removing and installing
    • Cooling system components, removing and installing
    • Cooling system components, body side
    • Cooling system components, engine side
      • Notes
      • Engine code AEG (up to model year 1999)
      • Engine codes AEG, AVH and AZG (from model year 1999)
      • Engine codes BBW, BEV
    • Coolant hose connection diagram
      • Notes
      • Engine code AEG
      • Engine codes AVH, AZG, BBW, BEV
    • Cooling system, draining and filling
      • Notes
      • Draining
      • Filling
    • Radiator And Cooling Fan, Removing And Installing
      • Notes
      • Removing
      • Additional information and assembly work on models with air conditioning
    • Coolant pump, removing and installing
    • Thermostat, removing and installing
    • Radiator coolant fan (vehicles with engine codes AEG, AVH and AZG), checking
• 20 Fuel Supply
  • Fuel supply system components, removing and installing
    • Fuel supply system components, removing and installing
    • Fuel tank with attachments and fuel filter, removing and installing
      • Notes
      • Engine codes AEG, AVH, AZG, BEV
        • Notes
        • Installed position of flange of fuel delivery unit
        • Checking Switch Valve
        • Checking Pressure Retention Valve
        • Installation position of screw-type clip relative to fuel filter bolt
      • Engine code BBW
        • Notes
        • Installed position of flange of fuel delivery unit
        • Removing and installing fuel pressure regulator
    • Safety precautions when working on the fuel supply system
    • Rules for cleanliness
    • Fuel delivery unit, removing and installing
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
        • Notes
        • Removing
        • Installing
    • Fuel gauge sender, removing and installing
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
    • Fuel filter, removing and installing
    • Fuel Tank, Removing and Installing
      • Engine Codes AEG, AVH, AZG, BEV
      • Engine Code BBW
    • Crash fuel shut-off
    • Fuel Pump, Checking
      • Notes
      • Engine Codes AEG, AVH, AZG, BEV
      • Engine Code BBW
    • Fuel system, bleeding
  • Accelerator mechanism
    • Accelerator mechanism, servicing
    • Throttle cable, adjusting
      • Notes
      • Vehicles with manual transmission
      • Vehicles with automatic transmission
  • Electronic Power Control (EPC) system
    • Electronic Power Control (EPC) system
    • Function of EPC system
  • Evaporative Emissions (EVAP) system
    • Function of EVAP system
      • Notes
      • Engine codes AEG, AVH, AZG, BEV
        • Notes
        • Functional description of leak diagnosis
      • Engine code BBW
        • Notes
        • Functional description of leak diagnosis
    • Evaporative Emissions (EVAP) system components, servicing
      • Engine code AEG
      • Engine codes AVH, AZG, BEV
      • Engine code BBW
    • EVAP system, assembly overview
      • Engine codes AEG, AVH, AZG, BEV
      • Engine code BBW
    • EVAP system, checking using KLI 9210 tester
• 24 Multiport Fuel Injection (MFI)
  • Injection system, servicing
    • Component locations overview
      • Notes
      • Engine code AEG
      • Engine codes AVH, AZG
        • Notes
        • Position of relays in protective housing (on left in engine compartment)
        • Location: 6-pin connector -1- for Heated oxygen sensor (HO2S) before catalytic converter
        • Location: 4-pin connector -1- for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter
      • Engines: BBW, BEV
        • Notes
        • Position of relays in protective housing (on left in engine compartment)
        • Connectors, installed location
    • General notes on injection
    • Intake manifold upper part, disassembling and assembling
      • Notes
      • Engine code AEG
      • Engine codes AVH, AZG
      • Engine codes BBW, BEV
    • Intake manifold lower part, disassembling and assembling
      • Engine code AEG
      • Engine codes AVH, AZG
      • Engine codes BBW, BEV
    • Fuel rail with injectors, disassembling and assembling
    • Air cleaner, disassembling and assembling
    • Safety precautions
    • Rules for cleanliness
    • Intake manifold upper part, removing and installing
    • Technical data
  • Components, checking
    • Injectors, checking for leaks and quantity injected
      • Engine code AEG
      • Engine codes AVH, AZG, BBW
    • Fuel pressure regulator and holding pressure, checking
      • Engine code AEG
      • Engine codes AVH, AZG
      • Engine codes BBW, BEV
        • Notes
        • Checking fuel pressure regulator
  • Engine control module
    • Engine control module, replacing
    • Adapting components and functions
    • Engine control module Diagnostic Trouble Code (DTC) memory, interrogating and erasing
• 26 Exhaust system, Emission controls
  • Exhaust system components
    • Exhaust system components, removing and installing
    • Exhaust manifold, front exhaust pipe and catalytic converter with attachments
      • Notes
      • Engine code AEG
      • Engine codes AVH and AZG
      • Engine code BBW
        • Notes
        • Connectors, installed location
      • Engine code BEV
        • Notes
        • Connectors, installed location
    • Muffler with mountings
      • Notes
      • Checking installation position of double clamp
      • Installation position of mounting
      • Separating point on exhaust pipe
      • Aligning front muffler free of stress
    • Exhaust manifold, removing and installing
  • Secondary air injection system
    • Secondary air injection system
    • Function
    • Secondary air injection system components, removing and installing
      • Notes
      • Engine code AEG (up to model year 1999)
        • Notes
        • Secondary Air Injection pump relay -J299-, control number 100
      • Engines: AEG (from model year 1999), AVH, AZG, BEV
        • Notes
        • Position of relays in protective housing (on left in engine compartment)
        • Secondary Air Injection pump relay -J299-, control number 100
    • Combination valve, removing and installing
    • Combination valve, checking
    • Secondary air injection pump motor, checking
    • Secondary air injection solenoid valve, checking
• 28 Ignition/Glow plug system
  • Ignition Coil N152, Checking
    • Notes
    • Special tools, testers and auxiliary items required
    • Requirements
    • Test procedure
    • Start diagnosis
    • Checking voltage supply
    • Checking activation
    • Checking wiring
    • Final Procedures
  • Ignition system, servicing
    • General notes on ignition system
    • Ignition system components, removing and installing
      • Notes
      • Engine code AEG
      • Engine codes AVH, AZG BEV
      • Engine code BBW
    • Safety precautions
    • Test data, spark plugs