Characteristics
| Parameter | Value |
|---|---|
| Manufacturing | Audi Hungaria Zrt |
| Engine make | EA 896 |
| Years of manufacture | 2003-2010 |
| Cylinder block material | cast iron |
| Engine type | diesel |
| Configuration | V-type |
| Number of cylinders | 6 |
| Valves per cylinder | 4 |
| Piston stroke, mm | 83.1, 91.4 |
| Cylinder diameter, mm | 83 |
| Compression ratio | 16.4, 16.8, 17, 17.5 |
| Engine displacement, cc | 2698, 2967 |
| Engine power, hp/rpm | 163/2800 – 3000, 180/3300 – 4250, 190/3500 – 4400, 204/3500 – 4500, 225/3500 – 4250, 233/3800 – 4200, 240/4000 – 4400 |
| Torque, Nm/rpm | 350/1400 – 3300, 380/1400 – 3300, 400/1400 – 3250, 450/1450 – 3250, 500/1500 – 2250, 500/1500 – 3000, 550/1500 – 3000 |
| Environmental regulations | Euro 4, Euro 5 |
| Turbocharger | Garrett GTB1756VK, Garrett GTB2260VK, BorgWarner (KKK) BV50 |
| Engine weight, kg | ~215 |
| Fuel consumption, l/100 km | city: 11.0, highway: 6.0, mixed: 8.0 |
| Oil consumption, gr./1000 km | – |
| Engine oil | 5W-30 |
| How much oil in the engine, liters | 8.3 |
| Oil change is carried out, km | 10000 |
| Operating temperature of the engine, deg. | ~90 |
| Engine life, thousand kilometers | Factory data: -, in practice: 500+ |
| Tuning, h.p. | potential: ~280, without loss of resource: – |
| Motor installed | Audi A4, Audi A4 Allroad, Audi A5, Audi A6, Audi A6 Allroad, Audi A8, Audi Q5, Audi Q7, Volkswagen Touareg, Porsche Cayenne, Volkswagen Phaeton |
VW EA896 engine reliability, problems and repairs
Since the end of 2003, Volkswagen Group cars have been equipped with EA 896 series engines, which replaced the EA330 model. These engines are based on a V-shaped cast iron block with a 90° camber angle, have a balanced shaft, a crankshaft with a piston stroke of 91.4 mm, connecting rods with a length of 143.1 mm and pistons with a compression height of 46.3 mm.
In 2004, a 2.7 TDI was created on the basis of the 3-liter motor by installing a short-stroke crankshaft (83.1 mm).
All EA 896 series motors are equipped with two 12-valve aluminum block heads with hydrocompensators. The timing mechanism is driven by chains, the life of which is not stated by the manufacturer.
These engines received Common rail fuel supply system on piezoelectric injectors, with Bosch fuel injector, designed for a pressure of 1800 bar.
However, in 2015, there was a scandal involving VW Group diesel cars in the US. The EA 896 series motors were also involved in this scandal, so the Euro 5 rating is not reliable enough.
Modifications of the EA 896 engine
EA 896 series motors have a huge number of modifications (more than 30), which are divided into two generations: 1st generation or G1 with indexes A and B (3-letter), 2nd generation or G2 (EVO) with index C (4-letter).
- Capacity 2698 cc: BPP, BSG, CAMA, CAMB, CANA, CANB, CANC, CAND, CGKA, CGKB.
- Capacity 2967 cc: ASB, BKN, BKS, BMK, BNG, BUG, BUN, CAPA, CARA, CARB, CASA, CASB, CASC, CATA, CCLA, CCWA, CCWB, CDYA, CDYB, CDYC, CEXA, CEXB, CMHA, CPNA, CPNB.
The main difference in the second generation of motors is the change from Bosch CP3 to Bosch CP4 fuel injectors, which allows to develop maximum pressure in the ramp up to 2000 bar. There are also changes to the intake with a new intake manifold, heads, cooling and other features. On the second generation, the timing chains have been repositioned, the EGR valve has been modified, and new turbos have been applied.
The Garrett GTB1756VK turbo was used on the 2.7-liter motors.
EA 896 engine problems and shortcomings
Intake manifold flaps. Already at a mileage of 50 thousand kilometers. flaps may not work properly due to fouling or malfunction of the servo drive. Cases of breakage of the flaps are extremely rare, but in case of high mileage it is better to remove the flaps together with EGR.
Transmission timing chains
The motor uses as many as 4 chains and several hydraulic tensioners, the resource of the whole mechanism is about 250 thousand kilometers. The problem is only one – location, the chains are located at the engine shield on the side of the box, so when replacing the chains at least need to remove the box. The cost of all manipulations will start from 1000€.
Piezoelectric injectors. Nozzles from Bosch are very reliable, the resource of about 250 thousand kilometers. The cost for one piece is 400€. Repair is possible, but without guarantees.
TNVD
In the second-generation motors there was a defect, the pump could start chasing chips through the fuel system for no apparent reason. Almost all motors with such a problem have undergone a service program to replace defective units. The resource is about 300 thousand kilometers.
heat exchanger
At mileage more than 200 thousand km. begin to crack the gaskets, usually the problem helps to solve the repair kit for 40 €.
Thermostat
On some modifications there are 2 thermostats, the main one and for EGR, this is the main catch. When replacing the EGR thermostat, you need to change one of the cooling system hoses. The resource of about 100 thousand kilometers, it is better to plug EGR and remake the system under one thermostat.
There is no regulation on glow plugs replacement, but on average they last 60-100 thousand kilometers. The service life of the turbine is very long and can exceed 300 thousand kilometers. The crankshaft damper pulley goes more than 300 thousand kilometers. It should be noted that the EA 896 series engines are extremely reliable and with proper maintenance do not ask for any repairs up to 200 thousand kilometers.
Tuning engine EA 896
Chip tuning c 2.7 TDI can get about 220 – 230 hp and 480 – 500 N-m. C 3.0 TDI about 270 – 310 hp and 550 – 600 N-m. The resource is actually not affected.
Hybrid turbo, more efficient fuel injection, intercooler replacement, removal of all ecology, custom exhaust – the result is about 320 – 400 hp and 700+ N-m.
MOTOR RATING: 5