VW 2.0T TSI - Full Engine Rebuild
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- เผยแพร่เมื่อ 13 ก.ค. 2024
- Hey everyone! Come along for a full rebuild on the Volkswagen 2.0T TSI engine out of our 2010 MK5 Jetta Wolfsburg! The engine was over-revved after a money shift from 3rd to 2nd, and in this video we carry out a deep repair and refresh the engine in the process, along with installing some Integrated Engineering forged drop in H-Beam connecting rods. Enjoy the video! Please like, share, and subscribe :)
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00:00 Intro
00:36 Explanation of what happened
03:58 Valve guides
12:47 Lapping valves
16:50 Valve stem seals
17:40 Valve springs/retainers
21:20 Pistons/rods/bearings
42:12 Cylinder head
44:32 Oil pan/oil pump
48:47 Valvetrain/camshafts
52:41 Valve cover/PCV
56:18 Balance shafts
1:02:30 Timing chains
1:13:37 Water pump
1:14:29 Vacuum/fuel pump
1:16:41 Timing covers/turbo
1:17:32 Rear main seal/clutch
1:20:14 Engine in the car
1:21:05 Intake manifold/finishing touches
1:27:47 Starting the engine
Mods in this video:
1. HPA K04 Software
2. HPA SHS Coilovers
3. HPA Hyrbrid K04 Turbo
4. 034 Motorsport Mounts
5. DG Sigma 6 Shortshifter
6. Wagner Tuning Intercooler
7. Snow Performance Stage 1 WMI
8. Integrated Engineering H-Beam Rods
9. One Step Colder NGK Spark Plugs
10. South Bend Stage 2 Daily Clutch
11. Spulen Dogbone Mount Insert
12. 42DD 3" Catted Downpipe
13. Custom Catback Exhaust
14. Neuspeed P-Flo Intake
15. Mahle Rod Bearings
16. R8 Coil Packs - ยานยนต์และพาหนะ
![fellow fellow - Proud [OFFICIAL MV]](http://i.ytimg.com/vi/9uZF7BlUQPE/mqdefault.jpg)
I rebuilt over 20 A4 engines at Audi during the 2015 oil consumption recall. One thing Audi (they created the EA888 2.0 TSI) really pushes is to never hone the cylinder walls of these engines. They are honed with a laser process and if you break that the engine will burn oil. Also, if your engine has the two piece oil control rings (one thick ring with a spring behind it) replace the pistons. Those rings plug with carbon anywhere from 50-70k miles and it will use a lot of oil. The newest pistons have a three piece ring (waffle ring). I put these pistons in my 2013 A4 because it was using a quart of oil every 600 miles. I have about 12k miles on my engine now, it doesn’t use any oil at all. I go 5k miles between oil changes and the oil level never moves off full.
Thank you for the indsight, this is really interesting. Would explain why my mk6 gti burns that much oil.
Will def follow those recommandation when rebuilding time comes !
You guys are the only ones who took their time explaining everything.
Very well detailed content .
Gonna subscribe
Thank you for the kind words :)
look in to Naptown tuner as well, his channel is like a college course for this engine.
You guys are awesome, love not only the speed3 content but the full channel!
Just gonna say, as an engine builder, when installing pisons, keep the crank journal low as possible which saves you from any risk of nicking it with the con rod. Otherwise a very good video fro. You guys, not many people have the skills to strip and rebuild an engine.
Thanks for the advice and kind words my friend :)
@@WannabeTuners always happy to help a mechanic out! I know its not easy rebuilding an engine without access to a machine shop and those that were talking about plastigauge, many modern engines now work of engine codes along as the crank is standard, people can order bearings for mains and big ends off the engine code and 99.99% are very accurate
Funny you say that first build i did as a technician was a Chevy Cruze con rod bent oil squirter . Nightmare from a 1 second mistake
Great video man, I'm in the same situation I got stock for a sec, I came back to your video to see of you got your rings gapped, the manual says a gap of 0.009" but the Mahle ring specs says 0.019" for a boost less than 15 psi. Should I go with Mahle specs since those are the rings I have?
@@hectorurrea2993 did you ever get an answer on this question?
I just finished watching the entire video. Man! Gutsy move rebuilding it! I salute you both for putting the engine back together with just a torque wrench! Amazing rebuild. Awesome. I money shifted my engine as well, and it was a swapped MK6 R engine too on a MK5 GTI (same FSI, but just stronger internals on the Golf R engine), luckily the pistons weren't scored, just my cylinder head broke. So I ended up just buying a new head.
Nice job tackling it yourself dude. It's a great feeling the first time you do a job like this successfully 👍🏽
Thanks man! It was definitely a great learning experience
Awesome stuff, nicely done guys. I just sat and watched the whole video in one shot lol
GREAT JOB, posted the video. Thank you for many
Best video I seen of rebuilding an engine, thanks for the help.
It takes pride to admit when you money shift.
Mad respect, I may be entering the VW scene with an 8P swapped mk5 if all goes right.
I got my first vw it’s a stage 3 2.0 vw With a k02 turbo upgrade
It’s so fun
@@roccovelasco7159 The KO2 is a great pusher, been in a stage 1 2.0....bet stage 3 is a blast!
I didn't end up getting the above, got custody of my kids so priorities shifted.
One of the best videos I've watched in a long time thank you.
I am an aspiring mechanic and this helped me understand more about how an engine works, thank you
From what I understand from owning a 2.0 the weak links are the pcv, timing chain and it needs a oil catch can
just the best petrolhead channel, you are awesome !
Another banger vid from both of yall🔥 looking forward to see some pulls 😌
I think you two fellas are doing fine work here, and I’ve learned a great deal. You are officially my favorite Canadians.
Thanks eh, glad to have been of use for ya ;)
Buen video 💪🏻 hello from Argentina 🇦🇷🇺🇸
Have been referencing this video for information, super helpful man, thank you so much. Have a mk7 gti , #4 0 compression, blew out the whole side of the piston and rings
How did that happen lol
Im rebuilding the same engine.. very intimidating engine to rebuild.. I dont have the service manual.. who needs manuals!.. it boosted my confidence on the build! Thanks
Go with a k02 turbo upgrade from APR u won’t regret it
This is a great engine. The 2012 Q5 2.0 litre pulls hefty car! It can also pull a trailer.
My stage 3 is pushing almost 400 pounds of torque it’s beasty
What a wonderful upload.
Great detail on the valve guides thank you
Great job, awesome video!
You have no idea how much i appreciate this video. And i love your check engine tattoo haha getting one for sure. You did the classical reassurance towards the end there by repeating everything you've done hahaha 🤣 i think we all do that. Let me know if you are ever in mid Florida, I'd PAY to sit down with you for real
Keep up the good content guys!!!🤙
Eyy listening to this in my crane at work!
*osha has entered the chat*
Great video! I will be attempting this this week. 👌
Awesome all the best!
Very nice for doing it at home!
Quality stuff
Great job
I have this same engine in my 2015 VW EOS. It’s nice to see what my engine looks like!
Little engines with big personality!
Awesome video! It will serve great reference when I do similarly on my Gen 3 EA888 from my 2014 MK6 GLI.
I guess the answer is budget. I would've gone with the iABED rear main seal upgrade. That's what I installed when I went Stage II Clutch/Flywheel for my Stage II Unitronic tune.
Is urs a manual or the DSG?
This was amazing 👏🏿
Thank you man amazing video 👍
Dude what a fantastic vid! Watched all of the ads for ya ✌🏼.
I’m about to do the same thing because the oil screen from the cam bridge got lodged in one of the bearings. Wish me luck, man!
Awesome thanks man, good luck!
Thanks bro, i m Learning so much.
Glad to hear man!
Congratulations , fine work indeed
Thank You :)
Very good video with lots of details information. The only thing that I would like to see or mention is how you change white Teflon injector seal. Thanks for posting !
Loved it!
/very nice video. I especially like your speech rate. It is slower than most people talk - and they talk too fast to comprehend. You set a nice pace.
Great job!
Thanks man!
Thank you so much🙏🏼
Can’t wait to watch this later! Always great content!
Are there many major differences for the FSI?
The Timing area is different among other things but I can't remember all the differences
Nice work 👏 👌 👍
Thank you :)
Great video! I need to do the same plus few more things on my 2.0t due to oil consumption and low compression (115-120psi) this gives me a motivation to study how to rebuild this engine. Surprised you didn’t replace the factory oil rings with waffle shape rings while you’re there.
Bru what he did those aren’t stock pistons
Please do a good oil flush.
Buy the cheapest thinnest oil and which ever oil flush product you want.
Run the oil and additive for a half an hour at idle( occasionally reving engine to 3000rpm)
Drain and refill. Add half a quart of Lucas syn. oil stabilizer.
This will remove the carbon and gunk between your rings, restoring compression and reducing oil consumption.
If this does not work, then proceed with your rebuild.
Nice job 👍
Thanks a lot 🙏
Nice job. 👍
Thanks man 😃
the tightening sequence for the main aluminum pick up oil pan starts with the long bolts; and work your way up/down to the other timing chain side.
Overall, excellent build, I use this video as reference when working on my 2.0t.
Thanks for the advice. Glad you enjoyed it :)
@@WannabeTuners Have heard mix input for the plastic exhaust balance shaft, some people re-use it, other ditch it, was the plastic black separator re-installed after the rebuild?
Awsome video I got my first VW last year. 2012 CC with a 2.0 TSI full bolt on APR stage 3 tune with a k02 turbo upgrade pushing 360ish Whp 380ish torque
This video was awsome in the case I rebuild the motor in the future.
Never done an engine rebuild but I’m mechanicaly inclined. lol always done my own car work.
148k miles on this car and it still runs great, other then the DSG transmission slipping sometimes. I know it’s gonnna need a new fly wheel and clutch 😂
Awesome thanks, happy to hear you're enjoying it :)
@@WannabeTuners yessir keep the 2.0 TSI Content coming :)
Also do you have videos on maintenance and things to look out for? Or essential mods for this engine like the weak points and stuff that would be awsome
I liked 👍 and subbed brother!
@roccovelasco7159 Oh man I wish! Unfortunately the car was sold a while ago due to financial constraints, but it was so much fun while we had it. I know we have a decent amount of info sprinkled throughout our videos of the car, but a lot of info in regards to common issues can be found online as well :)
Nice! Great work...:-)
Thanks man :)
You can get a set of cam locks made for this engine when you are timing this engine. I have a set and used them when I had to do the timing chain service. It keeps the valve springs from moving the cams.
Honestly bro i watched this whole thing just to try Nd figure out what a part is. Still not quit sure. Honestly resorted to looking for help from people like you who know how to build and rebuild the engine.😭😂
Did you ever get your problem part identified and worked out ?
🤦♂️🤦♂️🤦♂️ they are keepers my man
I have this exact same car. Love it, but it is running a bit rough and has an oil leak somewhere. I have been thinking about doing something like this to get another 100k miles out of it. Thank you so much for documenting the process.
Thank you, really appreciate your comment!
@@WannabeTuners hey. Any chance you could provide some resources? I would like to start reading up a bit more on this. I have a Bentley manual, but I am wondering where you get all the details like, needing to put the balance shaft in the freezer, and torque patterns. Also trying to figure out best strategy for a parts and tools list.
@@johnathonkarcz6605 those details were in the repair manual I bought from the "all data diy" website. I think it was like 30bucks for a year subscription which has expired for me now. They have lots of pictures and torque specs for most of the fasteners on the engine. The freezer recommendation was a note at the bottom of the page where they recommend commercial freezing spray. They sometimes don't explain things perfectly but it got me close enough. I dont know how it compares to the Bentley manual, but I got pretty much all my info from that and analyzing humble mechanic's tear down videos of these engines. Hope that helps!
@@WannabeTuners Hey, I just noticed that you replied (4 months later). I wanted to thank you for taking the time. I really appreciate the info. I will check out that site and grab a subscription. I already watch enough humble mechanic videos. haha. thanks again.
That engine light tattoo tho LOLOL
Hi. That is exactly what i was afraid of. I used plastics boxes separating diffèrent parts. Thank you for your explanation.
Brooo I cant believe I just stripped the same bolt going into the side of the main bearing you did lmao. It's not too bad I could take it out if need be but its torqued and wont be going nowhere for a while lol wish me luck I still have a lot to go.
Hahaha good luck man!
Awesome video! That’s a hell of a job for 2 dudes in a garage to complete. You guys seemed very organized and had all things considered throughout the process. Any reason you didn’t pull he engine and trans out together versus leaving the trans in the car up on blocks?
Thanks! No real reason for leaving the trans in. Clutch fluid line can be a bit messy when disconnected but not a huge deal. Once the front clip of the car is off there's lots of room to play with trans and engine so I guess we just did it this way out of randomness
Beautiful work, i wonder how long it took 😀
Very nice engine rebuild. . . and a beautiful chronograph watch, too! Is that a *Tissot* ?
Haha thanks! Yea it's a PRC200, I like the yellow on the black dial(not automatic)
Bout to to the same with mine fighting the urge to go h beam and integrated Pistons. Or stock and updated Audi Pistons. Just purchased a 23L before oil scraper ring went .
Nice job but to do the valve job faster grinding the compound against the seat, u could've attach a hose to a drill and thr end of the valve rod and spin it around. The hand tool is fine but takes long.
Hey can we get a spec sheet for how much torque for the various bolts? I want to get into my 2.0 but I kind find the service manual
Alldata was used to get the torque specs, but unfortunately we no longer have access to it.
The tattoo on his arm tells me. Real car mania. good!
I'm looking at stuck injectors and needing a new valve cover gasket.
Any advice in this gasket replacement and possibly leaving the injectors attached to the valve cover?
Great vid.
What was the manual used for all torque specs?
It was an All Data DIY subscription
Welll nowwwww, in a couple months you can get a nice garret turbo and not have to worry about rebuilding the motor
Great video! So on a CCTA cylinder head, when it jumps time and bends the intake valves. You have to replace all the guides as well?
Yes because if the valves got hit by pistons there's a good chance the guides got damaged by the valve stems pressing up against them
MONEY SHIFT!!
coffee filters work wonders instead of paper towel or microfibres
Hi, do you know what the plastic sleeve on exhaust balance shaft is for? Is it really needed?
Great video ! How did you find taking the crank bolt spacer back off and fitting aux pulley and bolt back in?
Its a little scary because you don't want to turn the engine backward and cause the timing chain to jump. I tried to make sure I didnt snug the crank bolt too tightly when I had the donut on. Once the bolt was loose I just went very slow and made sure the room was quiet so that if something jumped/skipped, i would hear it. Go slow, no sudden movements, treat it like a bomb haha
@@WannabeTuners haha I hear that, thanks dude that’s great. No one seems to show that in any videos haha👌🏼🤘🏼
Nice video man.i'm trying to do mine .i see that the upper crankshaft bearing are red .how did get this information? I know the the lower one are mentionned on the crankshaft itself. Thank you
Why not do some performance upgrades while it was apart? Perfect time to do some porting and polishing of the intake and exhaust runners of the head. Would have gained some noticeable power with some simple porting and polishing work of the head. Also a good time to clean up all the oil travel lanes to get the oil back to the pan as fast possible. Did you balance the motor? always a good idea to match weigh all the pistons, rods etc to get a balanced rotating assembly. Lastly upgrade the piston rings to a set of custom total seals
At the time I was on a very tight budget and just wanted to get it running. This was the second time that the engine had to be rebuilt, so money was tight. But yes I totally agree! If going this far, might as well do it proper lol
Very nice video! My EA888 1.8 is starting to consume a little more oil than I'd like. Runs great, but when that day comes, I'll use this video to help. Will upgrade the rods and pistons (updated Audi design). The timing seemed like such a PITA, but it's not that bad. Thanks!
Thanks brother!
great video curious what type of metal the valve guides are made of anyone know ?
Thanks, I was stumped. I'm guessing bronze but for all I know it could be another alloy where the coppery colour comes from
The valve keepers on a1.8t are really fun,what a pain! Cause on 1.8 the keepers are in like spark plug holes .it was a lot easier on your 2.0t tsi. ty for video.oh yeah what was the reason for the new valves to be 6.0 mm? Ty
Thanks! oh damn that sounds like a pain! The valves are 6mm so when I bought the new guides they were all like 5.5-5.9mm and the valves just wouldn't slide into them at all, so I reamed them out to 6mm
Can we use "Permatex 82180 Ultra Black Maximum Oil Resistance RTV Silicone Gasket Maker" for the valve covers, Timing case and oil pan? U mentioned about ultra black while installing the upper oil pan but later you used the anaerobic gasket maker 51813!
Where did you buy the valves and seals?
Thanks for the video. Following it slowly to get my engine assembled. Do you have any advice on HLA inspection? Or preparation for installation? Thanks
Hey thanks! What do u mean by HLA inspection?
@@WannabeTuners Well, do you clean them before installing them? Two of the HLA don’t have movement and all the rest you can squeeze in and out. I watch a few videos that you have to preload the HLA? Did you do any of that?
I just spoke to my buddy who did most of the work and research. He said that his Hydraulic Lash Adjusters were moving freely and all he did was oil them up. If you're having any issues with them, I would replace.
What parts should I upgrade/ replace and keep? Im on the verge of doing a rebuild but im terrified and im on a budget
This video was great, I guess you weren't kidding when you said you were under a budget. Drinking bud? Yikes. Where can I send you a case of real beer?
hahaha! I do like my share of craft beer but bud is good when I want a lot of them without forgetting to tighten fasteners :) Cheers!
Did you put a gauge on it to check runout, or did you just go with it? I'm pretty close to trying to rebuild my FSI with H-Beams from IE, but it will be my first time doing internals ever, so I'm trying to get as much info as I can before i decommission my MKV GTI for however long it takes me to pull the engine and do the work.
We took a risk and just went with it. We used the same standard sized bearings that were removed. No issues to report and it's been almost 2 years since completing the rebuild:)
Excellent mi amigo...very good
Awesome video guys! What sealant did you use on the lower timing chain cover? And did you replace the old one or reused it?
I used Permatex ultra black. The first time I did the cover I replaced it, but in this video I reused it because I was careful to take it off without bending it. I recommend replacing it. It hasn't leaked yet but it's risky because it has the potential to cause a huge leak, either around the pulley or around where the flange meets the block
@@WannabeTuners thanks bro! Really great video and thanks for the reply, I’ll get it ordered
Did you replace the main bolts as vw recommended new as stretch bolts
Off the top of my head I don't recall if we replaced them or not, but since we were following the workshop manual, there is a good chance that we did. If VW recommends replacing them, then I'd say definitely do it :)
You are not supposed to use anaerobic sealant on that cam craddle. Loctite 5970 or any other quality silicone goes there. Thats why there is that ditch.
Hello Wannabe Tuners. Does the elring valve stems brand last long? Im doing a rebuild of my 2.0 tfsi. And Im thinking of using them
Hi sorry I don't have any knowledge on those valves
I remember an Audi defender told me the 2litre tfsi was designed to burn oil...OH REALLY...thats why there was a major piston and ring replacement campaign...
Hello ,
Would you have a link or site for the connecting rods you had taken?
Amazing i have my vw cc 2.0 tsi engine down and its time for new pistons i need special size or just looking on google ?
Autozone or ebay???
If u get new pistons and rings, it'll probably be good idea to get a machine shop to check and see if the cylinders are out of round and hone the cylinders to help the new piston rings bed in correctly 😉
Awesome vid man I enjoyed the whole thing. I'm rebuilding my Audi 2.0t CNCD engine soon with 220,000km this is very good for reference (being a similar engine). I was just wondering what your budget was, or if you could give a rough estimate. Reason I'm asking is because I want to do a rebuild myself for the fun of it but an engine swap might turn out alot cheaper doing it on my own. Also I have to factor in tools and equipment because the little that I have are old and worn. I basically watched this twice really good vid!
Hey thanks! And awesome! I think it ran me around 4000CAD if I recall correctly. I already had the special tools (crank pulley counter hold, that than VVT camshaft solenoid tool). Depending on what needs replacing, it could run you more. Suppliers I used were GermanParts, GermanOem, Rock Auto, the VW dealership and ECS Tuning. At first I found a replacement used engine for 3500 but thought I could do the work cheaper lol. It was hard finding engines. If I had the space I would have bought a salvage vehicle to harvest from! Hope that helps!
@@WannabeTuners helps heaps thank you so much I really appreciate it!
@@WannabeTuners is there a six month review of the build?
@@psiturbo Unfortunately the car has been sold
I’m just trying to figure out how to do the head gasket on this 2012 vw cc 2.0 t 😩
Main oil seal should be replaced with a billet unit.
I think it is iabed or iAbed
(the most popular anyway)
Hi, anyone know where I can get valve seat replacements for 2.0 tsi? Cheers
You could have put your valve guides in the freezer for a few hours before installing.
How do you get the valve guides out?
Hi guys, where did you buy your connecting rod bearings? Can you please let me know
If memory serves me right, the OEM main bearings were bought from the dealership, and the rod bearing bought from Integrated Engineering
Hi,do you remember the torque specs for the actual balancer shaft bolts? ,the ones on the shaft themselves.
I don't remember and my subscription to the manual expired but I think I just went snug on those with blue loctite
really informative. but music to loud spoils your vid
Are all rockers arms the same for intake & exhaust?
I am not 100% sure on this, however they all looked the same. I think it's best to double check with the parts department at the dealership.
how hard was keeping the trans in the car? about to do it on mine, do u still have to disconnect the shifter linkage?
The transmission was actually fully removed both times that this engine was out of the car, so shifter linkages and both front half shafts were fully removed. We used a pump jack to support and separate the transmission from the engine.