VAG BWA — 2L I4 16V DOHC TFSI (Direct Injection turbo K03) Engine
2L I4 16V DOHC TFSI (Direct Injection turbo K03) · 200 hp · 280 Nm
Values cited from a licensed workshop database.
On the BWA, spark plug: 25 Nm.
Engine overview
Manufacturer
VAG
Displacement
2 L
Configuration
I4 16V DOHC TFSI (Direct Injection turbo K03)
Power
200 hp
Torque
280 Nm
Production years
2005-2009
Fuel type
Petrol
Vehicles with this engine
Known failures & weak points
Timing chain tensioner (cam chain side) fails → cold-start rattle → chain jumps → bent valves. PREVENTIVE replace at 100k km.
HPFP (high-pressure fuel pump) cam follower wears through → no-start. Inspect EVERY oil change after 50k km.
Intake valve carbon buildup (no port injection on DI engines) → misfire, rough idle.
Diverter valve (N249) — same as AGU, diaphragm tears.
PCV / crankcase breather (oil separator) diaphragm hardens and cracks over time, causing excessive crankcase pressure and boost- or vacuum-related fault codes. VW revised the oil separator design more than once during production — fit the latest-revision part when replacing it.
Oil consumption — piston ring design issue — many burn 1L/2000km. Some VW extended warranty on this. Newer rings improve it.
Common torque specifications
| Head Bolts | M11 — 35 Nm + 90° + 90° + 90° + 90° (TTY) unconfirmed |
|---|---|
| Crank Pulley Bolt | 150 Nm + 180° (TTY, M16) unconfirmed |
| Spark Plug | 25 Nm |
| Hpfp Cam Follower Bolt | 10 Nm unconfirmed |
| Flywheel Bolts | 60 Nm |
| Connecting Rod Bolts | 45 Nm + 90° |
| Oil Drain Plug | 30 Nm |
Figures marked unconfirmed could not be cross-checked against a workshop source. Verify against the vehicle’s own documentation before tightening.
Factory specifications
Values from the manufacturer documentation for this engine.
Engine (general)
| Engine code | BWA |
| Capacity | 1984 cc |
| Idle speed | 640 - 840 rpm |
| Normal | 11.0 - 14.0 bar |
| Minimum | 7.0 bar |
| Differential limit between cylinders | 3.0 bar |
| Oil pressure | >2.0 / 700 - 840 2.7 - 4.5 / 2000 bar/rpm |
Engine (petrol)
| Fuel system (make and type) | Motronic MED 9.1 |
| Number of cylinders | 4 |
| Firing order | 1 - 3 - 4 - 2 |
| Spark plugs (make and type) | Bosch F6KPP 332 S VW/Audi 101 905 631 B |
| Spark plug gap | 0.9 - 1.1 mm |
| Injection pressure/system pressure | 40 - 120 bar |
| Fuel pump pressure | 4.0 - 6.0 bar |
| Fast-idle speed | 2500 - 2800 rpm |
| CO at fast-idle speed | < 0.3 % |
| Oil temperature during test | 80 °C |
| Lambda | 0.97 - 1.03 |
| Conditioning catalytic converter | 2 min |
Cooling system
| Cap pressure | 1.4 - 1.6 bar |
| Thermostat opens at | 87 °C |
Electrical
| Alternator | 110 140 A |
| Battery | 60/280A 61/330A 72/380A Ah |
Brakes
| Disc diameter, front | [НЕ е една стойност — зависи от изпълнението] 1ZF = 280 1ZC = 280 1ZM = 280 1ZE = 288 1LJ = 312 1LU = 345 1LT = 345 mm |
| Disc thickness (ventilated), front, min. | [НЕ е една стойност — зависи от изпълнението] 1ZF = 22 1ZC = 22 1ZM = 22 1ZE = 25 1LJ = 25 1LU = 30 1LT = 30 mm |
| Disc thickness, front, min. | [НЕ е една стойност — зависи от изпълнението] 1ZF = 21 1ZC = 21 1ZM = 21 1ZE = 24 1LJ = 21 1LU = 27 1LT = 27 mm |
| Brake pad thickness, front | 14 mm |
| Brake pad thickness, front, min. | 2 mm |
| Disc diameter, rear | [НЕ е една стойност — зависи от изпълнението] 1KQ = 255 1KD = 255 1KZ = 286 1KY = 286 1KJ = 286 mm |
| Disc thickness, rear | [НЕ е една стойност — зависи от изпълнението] 1KQ = 10 1KD = 10 1KZ = 12 1KY = 12 1KJ = 12 mm |
| Disc thickness, rear, min. | [НЕ е една стойност — зависи от изпълнението] 1KQ = 7 1KD = 7 1KZ = 9 1KY = 9 1KJ = 9 mm |
| Brake pad thickness, rear | 12 mm |
| Brake pad thickness, rear, min. | 2 mm |
Steering and wheel alignment
| Standard suspension | PR G48/G49 |
| Toe-in, front | 0° 10' ± 0° 10' ° |
| Camber, front | -0° 37' ± 0° 30' ° |
| Max. difference left side - right side | 0° 30' ° |
| Castor, front | 7° 40' ± 0° 30' ° |
| Toe-in, rear | 0° 10' ± 0° 10' ° |
| Max. difference left side - right side | 0° 20' ° |
| Camber, rear | -1° 20' ± 0° 30' ° |
| Heavy-duty suspension | PR G59/G60 |
| Camber, front | -0° 27' ± 0° 30' ° |
| Castor, front | 7° 28' ± 0° 30' ° |
| Sport suspension | PR G50/G51 |
| Camber, front | -0° 41' ± 0° 30' ° |
| Castor, front | 7° 47' ± 0° 30' ° |
| Camber, rear | - 1° 20' ± 0° 30' ° |
| Sport suspension | PR G61/G62 |
| Camber, front | - 0° 30' ± 0° 30' ° |
| Castor, front | 7° 34' ± 0° 30' ° |
| Sport suspension | Cupra PR G63 |
| Camber, front | - 0° 41' ± 0° 30' ° |
| Camber, rear | - 1° 45' ± 0° 30' ° |
Wheels and tyres
| Permitted tyre and rim combinations | 205/55 R 16 91V (6J x 16) 205/55 R 16 91V (6.5J x 16) 225/45 R 17 91W (7J x 17) 225/40 R 18 91W (7.5J x 18) 225/40 R 18 92Y (7.5J x 18) 225/50 R 17 94W (7.5J x 17) |
Capacities
| Engine sump, incl. filter | 4.6 l |
| Gearbox refill | 2.0 l |
| Gearbox refill after overhaul | 7.0 l |
| Cooling system | 7.5 l |
| Air-conditioner refrigerant | 525 ± 25 g |
| Air-conditioner compressor oil | 140 ± 10 ml |
| Air-conditioner compressor oil | 110 ± 10 ml |
| Air-conditioner compressor oil | 120 ± 15 ml |
Torque settings
| Cylinder head bolts — Stage 1 | 40 Nm |
| Cylinder head bolts — Stage 2 | 90 ° |
| Cylinder head bolts — Stage 3 | 90 ° |
| Spark plugs | 25 Nm |
| Oxygen sensor | 55 Nm |
| Wheel nuts | 120 Nm |
Emissions
| Emission code | 70/220*2003/76B |
| Emission standard | Euro 4 |
| CO2 average | 190 g/km |
| CO | 0.260 g/km |
| HC | 0.046 g/km |
| NOx | 0.011 g/km |
| HC NOx | 0.057 g/km |
Engine codes in the same family
The same code prefix usually means the same block with a different output, fuel or model year. Procedures are often shared — check the code on the engine plate.
Workshop procedures for this engine
Step-by-step procedures from the workshop database, carrying 222 torque figures.
- Removing and installing camshafts · 39 torque figures
- Exploded view - sump/oil pump · 22 torque figures
- Exploded view - cylinder head · 22 torque figures
- Checking fuel pressure sender G247 · 19 torque figures
- Installing toothed belt · 17 torque figures
- Removing and installing sealing flange (gearbox end) · 13 torque figures
- Removing and installing high-pressure pump · 16 torque figures
- Removing and installing camshaft adjuster · 14 torque figures
- Removing and installing injectors · 11 torque figures
- Removing and installing turbocharger · 7 torque figures
- Removing and installing sump · 9 torque figures
- Renewing vacuum unit for turbocharger · 4 torque figures
- Removing and installing throttle valve module J338 · 6 torque figures
- Removing and installing engine control unit J623 · 6 torque figures
- Adjusting vacuum unit for turbocharger · 3 torque figures
- Removing and installing balance shaft assembly · 4 torque figures
- Sump - exploded view · 6 torque figures
- Removing and installing vacuum unit for turbocharger · 3 torque figures
- Removing and installing camshaft adjuster · 1 torque figures
- Removing and installing toothed belt (vehicles without separate toothed belt covers)
- Removing and installing toothed belt (vehicles with separate toothed belt covers)
- Removing cylinder head
- Golf5/EOS TFSI (AXX,BWA) one-piece timing cover Ed. 01/2007
- Passat5 TFSI (AXX,BPY,BWA) one-piece timing cover Ed. 01/2007
- Golf5/EOS TFSI (AXX,BWA,BYD) split timing cover Ed. 01/2007
Service intervals
| Oil Change Km | 10000 |
|---|---|
| Oil Spec | 5W-30 VW 504.00/507.00 (full synthetic, Castrol Edge LL) |
| Oil Capacity L | 4.6 |
| Coolant Spec | G12+ (red) or G13 |
| Coolant Capacity L | 7.5 |
| Timing Belt Note | Belt (crank→exhaust cam, also drives the water pump): VW 180,000 km; Audi/US TSB 110,000 mi. Renew belt + tensioner + water pump as a kit. Also a cam-to-cam CHAIN with hydraulic tensioner (real, well-documented EA113 fault: 0.5–1 s cold-start rattle → chain stretch → skipped tooth → valve contact; preventive tensioner replacement ~100k km) and an oil-pump/balance-shaft chain in the sump (weak sprocket). Do not confuse with EA888 (chain main drive). |
| Timing Belt Km | 180000 |
A/C system
| Refrigerant Type | R134a |
|---|---|
| Charge Grams | 525 |
| Compressor | Sanden PXE16 |
Pro tips from the field
HPFP cam follower check is THE #1 BWA preventive maintenance. Inspect at every oil change.
Walnut-blast intake valves at 100k km — restores 20-30 hp lost from carbon buildup.
Chain tensioner failure is well-known — replace preventively at 100k km even without symptoms.
BWA tunable to 270-300 hp stage 1 on stock turbo (K03 max ~290hp before becoming bottleneck).
Got a BWA problem? Ask for free.
Describe the symptoms — TorqFix replies with a diagnosis cited from verified workshop data.
Get free diagnosis →Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
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The story behind TorqFix →Workshop data on this page last updated 22 Aug 2026.