2.0l - Cylinder Head, Valvetrain - Engine Code(s): Cbfa & Ccta Audi A3 8P рестайлинг 2

Scheme 111

1. O-ring Replace Coat with oil before installing
2. Oil Dipstick Guide Tube
3. Bolt 9 Nm
4. Bolt 9 Nm
5. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «CAMSHAFT ADJUSTMENT VALVE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__camshaft-adjustment-valve-1-n205)
6. Seal Coat with oil before installing Replace if damaged
7. Bolt Tightening order «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
8. Upper Timing Chain Cover Removing and installing, refer to «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
9. Seal replace if damaged
10. O-ring Replace Oil before assembling
11. Alignment Pins Centering the cover
12. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__lower-timing-chain-guard-section)
13. Bolt Replace Tightening order «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
14. Shaft Seal For the vibration damper Replacing, refer to «VIBRATION DAMPER SHAFT SEAL»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__vibration-damper-shaft-seal) .
15. Plug Replace

Scheme 112

Tighten the bolts -1 through 5- in the sequence shown

Tighten the bolts to 9 Nm.

Scheme 113

Tighten the bolts -1 through 15 - in 2 stages in the sequence shown

1. Tighten the bolts to 9 Nm.

2. Tighten the bolts an additional 45°.

Timing Chain Guard Lower Section - Tightening Sequence for 8 Bolts

Tighten the bolts -1 through 8- in 2 stages

1. Tighten the bolts to 4 Nm.

2. Tighten the bolts an additional 45°.

Scheme 114

1. Bolt 9 Nm
2. Chain Tensioner Is under tension Disconnect the locking pin T40011 before removing
3. Timing Chain Tensioning Rail
4. Guide Bolt 20 Nm
5. Bolt 9 Nm
6. Control Valve 35 Nm Left thread On engine codes CBFA and CCTA with assembly tool T10352
7. Bolt Replace M6: 8 Nm plus and additional 90° turn M8: 20 Nm plus and additional 90° turn Replace
8. Washer
9. Bearing Bracket
10. Camshaft Timing Chain Guide Rail
11. Camshaft Housing
12. Camshaft Timing Chain Before removing, mark the direction of rotation with paint
13. Camshaft Timing Chain Guide Rail
14. Guide Bolt 20 Nm
15. Three Stage Chain Sprocket Crankshaft Installed location «CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)

Scheme 115

1. Both surfaces must -arrows- must line up across from each other.

Scheme 116

1. Bolt Replace 9 Nm
2. Balance Shaft Exhaust side Replace after removing Lubricate the bearing with engine oil Replacing, refer to «EXHAUST CAMSHAFT BALANCE SHAFT»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__exhaust-side-balance-shaft) .
3. Pipe for the Balance Shaft Installed location «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
4. Chain Tensioner 65 Nm
5. Cylinder Block
6. Balance Shaft Intake side Replace after removing Lubricate the bearing with engine oil Replacing, refer to «INTAKE CAMSHAFT BALANCE SHAFT»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__balance-shaft-for-intake-side) .
7. O-ring Lubricate with engine oil
8. Mounting Pin Lubricate with engine oil Installed location «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
9. Intermediate Shaft Sprocket For the balance shaft The intermediate shaft sprocket must be replaced if the bolt -12- is loosened.
10. Bolt Replace 9 Nm
11. Washer
12. Bolt The intermediate shaft sprocket must be replaced if the bolt -9- is loosened. Tightening order «INTERMEDIATE SHAFT SPROCKET TIGHTENING SEQUENCE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
13. Guide Rail For timing chain
14. Guide Pins 20 Nm
15. Tensioning Rail For timing chain
16. Guide Pins 20 Nm
17. Timing Chain Removing, refer to «BALANCE SHAFT TIMING CHAIN»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__balance-shaft-timing-chain)
18. Chain Sprocket Installed location «CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
19. Guide Rail For the balance shaft timing chain
20. Guide Pins 20 Nm

Scheme 117

1. The pin from the balance shaft pipe must fit into the groove -arrow

Scheme 118

1. Replace and lubricate the O-ring -1
2. The alignment pin -arrow- for the bearing pins must engage in the hole in the cylinder block.
3. Lubricate the bearing pins

Scheme 119

Tighten with a new bolt as follows

Tighten to 10 Nm using a torque wrench.

Rotate the intermediate shaft sprocket.

The intermediate shaft sprocket must not have any play. Loosen and tighten it again if necessary.

Tighten to 25 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

CYLINDER HEAD ASSEMBLY OVERVIEW

Note. Replace cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head. It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

Scheme 120

1. Cylinder Head Gasket Replace Installed position: the part number faces the cylinder head
2. Bolt 25 Nm
3. Transport Bracket
4. Bolt Tightening order «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview)
5. Cylinder Head Removing and installing, refer to «CYLINDER HEAD»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) Check for distortion «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview)
6. Cylinder Head Bolt Replace Observe sequence for loosening «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview) Observe sequence for tightening «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview)
7. O-ring Replace Lubricate with engine oil
8. Sealing Plugs 5 Nm With ball head for the engine cover
9. Cap With gasket
10. O-ring Replace Lubricate with engine oil
11. Sealing Plugs
12. Bracket
13. Bolt 9 Nm
14. Heat Shield
15. Bolt 20 Nm
16. Bolt 20 Nm
17. To the Intake Manifold/Turbocharger
18. Ventilation Pipe
19. O-ring No replacement part
20. Gasket No replacement part
21. Engine Cover
22. Bolt Tightening order «CRANKCASE VENTILATION, TIGHTENING SEQUENCE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
23. Crankcase Ventilation Observe sequence for tightening «CRANKCASE VENTILATION, TIGHTENING SEQUENCE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
24. To Intake Manifold
25. Gasket No replacement part
26. Gasket Replace if damaged
27. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/mechanical-hydraulic/#hydraulic-components-brake-system)
28. Bolt Tightening specifications, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/mechanical-hydraulic/#hydraulic-components-brake-system)
29. 9 Nm Engine code CBFA only
30. Secondary air injection (AIR) solenoid valve -N112- Engine code CBFA only
31. Gasket Replace Engine code CBFA only
32. Mounting plate
33. Bolt 9 Nm
34. Connecting piece
35. O-ring Replace Coat with coolant
36. Bolt 25 Nm
37. Transport Bracket
38. Bolt 9 Nm
39. Camshaft Position Sensor -G40
40. Partition Plate

Scheme 121

Note. The bolts are self-tapping. Only use Original bolts when replacing the cylinder head, since the cylinder head is delivered without a thread for the installing the crankcase ventilation. It is not permitted to cut the thread with a thread cutter.

Tighten the crankcase ventilation bolts to 11 Nm in -1 to 10- sequence.

Scheme 122

Remove the bolts -arrows-.

Loosen the cylinder head bolts in -1 to 5- sequence

Scheme 123

Tighten the cylinder head bolts in -1 to 5- sequence.

Tighten to 40 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

Tighten further 90° using a rigid wrench.

Tighten the bolts -arrows- to 8 Nm.

Tighten the bolts -arrows- 90° further using a rigid wrench.

Scheme 124

Check the cylinder head for distortion with the straight edge and feeler gauge in several places.

1. Maximum permissible distortion: 0.05 mm

VALVETRAIN ASSEMBLY OVERVIEW

Note. The cylinder head and the cylinder head cover must be replaced together. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons. Always replace gaskets and seals.

Scheme 125

1. Exhaust Valve Do not rework, only lapping is permitted Valve dimensions «VALVETRAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valvetrain-assembly-overview) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valve-guides-checking)
2. Cylinder Head
3. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valve-guides-checking)
4. Valve Stem Seal Replacing: cylinder head installed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valve-stem-seals-cylinder-head-installed) , cylinder head removed, refer to «VALVE STEM SEALS WITH CYLINDER HEAR REMOVED, REPLACING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valve-stem-seals-cylinder-hear-removed)
5. Valve Spring
6. Valve Spring Plate
7. Valve Retainers
8. Hydraulic Adjusting Element Do not interchange Lubricate contact surface
9. Exhaust Camshaft Removing and installing, refer to «CAMSHAFTS»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__camshafts) Check radial clearance using Plastigage (roller rocker lever removed) Radial play: 0.024 to 0.066 mm Run-out: maximum 0.04 mm
10. Cylinder Head Cover With integrated camshaft bearings Clean sealing surface, refacing is not permitted. Remove old sealant residue.
11. Bolt Replace Loosening «LOOSENING THE CYLINDER HEAD COVER»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) Tightening order «CYLINDER HEAD COVER TIGHTENING SEQUENCE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)
12. O-ring Replace Coat with engine oil
13. Sealing Plugs
14. Intake Camshaft Removing and installing, refer to «CAMSHAFTS»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__camshafts) Check radial clearance using Plastigage (roller rocker lever removed) Radial play: 0.024 to 0.066 mm Run-out: maximum 0.04 mm
15. Cap Replace Removing: with the cylinder head cover installed, pierce through one side of the cover with an awl and pry it out Installing «CAMSHAFTS»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__camshafts)
16. Intake Valve Do not rework, only lapping is permitted Valve dimensions «VALVETRAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valvetrain-assembly-overview) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valve-guides-checking)

Scheme 126

Loosen the cylinder head cover in a 1 to 6 sequence.

Scheme 127

Replace bolts.

Hand-tighten bolts in several stages in -1 to 6- sequence.

Tighten the bolts in a -1 to 6- sequence to 8 Nm using a torque wrench.

Tighten the bolts an additional 90° using a rigid wrench in the sequence -1 to 6-.

Note. Make sure the cylinder head cover is not tilted.

Scheme 128

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

FASTENER TIGHTENING SPECIFICATIONS

Timing Chain Upper Cover - Tightening Sequence

Tighten the bolts -1 through 5- in the sequence shown

Tighten the bolts to 9 Nm.

Timing Chain Lower Cover Tightening Sequence

Tighten the bolts -1 through 15- in 2 stages in the sequence shown

1. Tighten the bolts to 8 Nm.

2. Tighten the bolts an additional 45°.

Intermediate Shaft Sprocket Tightening Sequence

Tighten with a new bolt as follows

Tighten to 10 Nm using a torque wrench.

Rotate the intermediate shaft sprocket.

The intermediate shaft sprocket must not have any play. Loosen and tighten it again if necessary.

Tighten to 25 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

Cylinder Head Tightening Sequence

Tighten the cylinder head bolts in -1 to 5- sequence.

Tighten to 40 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

Tighten further 90° using a rigid wrench.

Tighten the bolts -arrows- to 8 Nm.

Tighten the bolts -arrows- 90° further using a rigid wrench.

Crankcase Ventilation, Tightening Sequence

Note. The bolts are self-tapping. Only use Original bolts when replacing the cylinder head, since the cylinder head is delivered without a thread for the installing the crankcase ventilation. It is not permitted to cut the thread with a thread cutter.

Tighten the crankcase ventilation bolts to 11 Nm in -1 to 10- sequence.

COMPRESSION PRESSURE, CHECKING

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Ignition Coil Puller T40039
3. Compression Tester V.A.G 1763
4. Adapter V.A.G 1763/6

Test Sequence

Note. Engine oil temperature min. 30 °C (86 °F) Battery voltage at least 12.7 V

Remove the engine cover -arrows-.

Scheme 129

Disconnect the electrical connectors -arrows- on ignition coils.

Scheme 130

Remove the ignition coils with the T40039.

Scheme 131

Remove the spark plugs using a 3122 B.

Check compression using V.A.G 1763 and adapter V.A.G 1763/6.

Note. Using tester operating instructions.

Operate starter until tester shows no further pressure increase.

Compression pressure

Install spark plugs. Refer to SPARK PLUGS, REMOVING AND INSTALLING .

Install the ignition coils with output stages. Refer to IGNITION COILS WITH POWER OUTPUT STAGES .

Note. By separating the connections, DTCs are stored to memory. After the test, check the DTC memory and erase, if necessary.

Check the engine control module DTC memory Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding".

VALVE TIMING, CHECKING

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN COVER

Remove the noise insulation. Refer to Removal and Installation

Remove the bolts -arrows-.

Lift the clamps -1 and 2- and remove the air guide pipe.

Scheme 132

Turn the vibration damper, from underneath, in direction of engine rotation to Top Dead Center (TDC) -arrow-.

Note. Use a ratchet with a 24 mm socket to turn the vibration damper. Always turn vibration damper in direction of engine rotation to TDC. Do not turn the vibration damper backward to get to TDC! If the arrow marking on the timing chain guard lower section is no longer visible, set the engine at TDC with the dial gauge -VAS 6079-, refer to ENGINE WITH DIAL GAUGE -VAS 6079- AT TDC, POSITIONING The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another -arrow-. The markings -1- on the camshafts must point upward.

Measure the distance from the outer edge -1- to the marking -2- on the intake camshaft.

* Specified value: 61 to 64 mm.

Once the specified value is reached, measure the distance between the marking on the intake camshaft -3- and the marking on the exhaust camshaft -4-.

* Specified value: 124 to 126 mm

Note. If one tooth has an offset, there will be a deviation of approximately 6 mm from the specified value. Install the timing chain once again if there is an offset.

ENGINE WITH DIAL GAUGE -VAS 6079- AT TDC, POSITIONING

Special tools and workshop equipment required

1. Dial Gauge 0-10 mm VAS 6079
2. Dial Gauge Adapter T10170- or Dial Gauge Adapter T10170 A
3. Extending Piece T10170A/1

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN COVER

Turn the crankshaft with the socket SW 24 on the vibration damper in the direction of the engine rotation until the markings -arrows- are on top.

Scheme 133

Remove the spark plug from cylinder 1.

Install the T10170/A- all the way into the spark plug thread.

Scheme 134

Insert the VAS 6079- with the T10170A/1- all the way and secure it with the locking nut -arrow-.

Turn the crankshaft slowly to maximum dial reading in the direction of the engine rotation. When the maximum dial reading is reached (Bottom Dead Center (BDC) of the meter) position the piston at Top Dead Center (TDC).

Note. Use a ratchet with a 24 mm socket to turn the vibration damper. Always turn vibration damper in direction of engine rotation to TDC. Do not turn the vibration damper backward to get to TDC!

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

Test Sequence

Insert valve into guide. Valve stem end must be flush with the guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

Determine tip clearance.

Scheme 135

Wear limit

Note. If wear limit is exceeded, measure again using new valves. If wear limit is still exceeded, replace cylinder head. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

CAMSHAFT ADJUSTMENT VALVE 1 -N205

Removing

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Scheme 136

Remove the bolts -arrows- and then the camshaft adjustment valve 1 -N205-.

Installing

1. Tightening specifications, refer to «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Coat the sealing ring and the O-ring with engine oil.

UPPER TIMING CHAIN COVER

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1783
2. Open End Spanner Insert AF 10 V.A.G 1783/1

Removing

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Remove the bolts -1 through 5- and remove the timing chain upper cover.

Installing

1. Tightening specifications, refer to «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta)

Installation is in the reverse order of removal, note the following

Note. Replace O-ring.

Coat the sealing ring and the O-ring with engine oil.

Install the timing chain upper cover using the V.A.G 1783 and V.A.G 1783/1, tightening sequence TIMING CHAIN COVER ASSEMBLY OVERVIEW

Install the camshaft adjustment valve 1. Refer to CAMSHAFT ADJUSTMENT VALVE .

LOWER TIMING CHAIN GUARD SECTION

Special tools and workshop equipment required

1. Locking Pin T10060 A
2. Counter Hold Tool T10355
3. Engine Support Bridge 10 - 222 A with Spindle 10 - 222 A /11
4. Lifting Tackle 2024 A
5. Bits T10099
6. Thrust Piece T10368

Removing

Remove the noise insulation in the center by loosening the fasteners -1 and 2-.

Scheme 137

Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Scheme 138

Remove bolts -arrows-.

Remove the air guide pipe by lifting the clamps -1 and 2-.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Scheme 139

Secure tensioner with T10060 A.

Remove ribbed belt from vibration damper ribbed belt pulley.

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Scheme 140

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Remove vibration damper bolt using T10355.

Remove the vibration damper.

Note. To avoid damaging the splines, only install the vibration damper bolt with the T10368.

Install the vibration damper bolt and T10368 again.

Scheme 141

Remove the idler roller -1-.

Tighten the lifting eye 2024 A /2 on the engine lifting eye using a collar nut -arrow-.

Scheme 142

Place 10 - 222 A on upper edge of web plates with the following tool parts

Scheme 143

1. Engine brackets 10 - 222 A /1, quantity: 2
2. Spindle 10 - 222 A /11

Tension the engine with the spindle.

Remove the subframe bolts -arrows- on the engine.

Scheme 144

Lower the engine approx. 55 mm.

Free up the wiring harness -arrow-.

Scheme 145

Remove the bolt -1- and remove the ribbed belt tensioner from the accessory assembly bracket.

Remove the engine support bolts with T10099.

Remove the engine support and the bolts.

Remove the bolts -arrows- and remove the oil dipstick guide tube from the timing chain cover.

Scheme 146

Disconnect the wastegate bypass regulator valve -N75- from the turbocharger -arrows-.

Scheme 147

Remove the turbocharger support -1-.

Remove the bolts -1 through 15-.

Pry off the lower timing chain cover; when doing this, begin at -1 and 2-.

Scheme 148

Note. To avoid deformation, do not hold between the bolting points.

Installing

1. Tightening specifications, refer to «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) «SUBFRAME ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-engine-assembly-engine-codes-cbfa-ccta)

Note. Note the expiration date of the silicone sealant. The cover must be installed within 5 minutes after the silicone sealant has been applied. Replace bolts which have been tightened to torque. Replace sealing rings, seals and self-locking nuts.

Spray the sealing surface with sealant remover and allow it to work.

Remove any sealant residue on the cylinder block using a flat blade scraper.

Seal off both sides of the seal with tape to prevent contamination.

Use a rotating plastic brush to remove any remaining sealing on the cover.

Scheme 149

Clean sealing surfaces, must be free of oil and grease.

Install the cover using the old bolts and tighten to 8 Nm.

Check between the cover and crankcase using a feeler gauge; the gap must not exceed 0.2 mm.

Note. If the gap exceed 0.2 mm, replace the cover. It is not possible to measure between the cover the upper section of the oil pan, however check the sealing surface for evenness.

Make sure both alignment bushings for centering the cover -arrows- are present.

Scheme 150

Cut tube nozzle at front marking (jet dia. approximately 3 mm).

Scheme 151

Apply the silicone sealant on the clean sealing surface of the cover as illustrated.

Scheme 152

1. Sealant bead thickness: 2 to 3 mm.

Note. The cover must be installed within 5 minutes after the silicone sealant has been applied. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

Mount the cover immediately and tighten the bolts, tightening sequence TIMING CHAIN COVER ASSEMBLY OVERVIEW .

Note. After installing cover, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

Check oil level. Refer to ENGINE, CHECKING OIL LEVEL

Further installation is in reverse order of removal, note the following

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

VIBRATION DAMPER SHAFT SEAL

Special tools and workshop equipment required

1. Locking Pin T10060 A
2. Counter Hold Tool T10355
3. Thrust Piece T10354
4. Thrust Piece T10368
5. Pulling Hook T20143

Removing

Remove the noise insulation in the center by loosening the fasteners -1 and 2-.

Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Remove bolts -arrows-.

Remove the air guide pipe by lifting the clamps -1 and 2-.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Secure tensioner with T10060 A.

Remove ribbed belt from vibration damper ribbed belt pulley.

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Remove vibration damper bolt using T10355.

Remove the vibration damper and attach the T10368.

Scheme 153

Remove the shaft seal with the T20143/2.

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Clean running and sealing surface.

Remove the T10368.

Pull the sealing ring -arrow- using the T10354 and the vibration damper bolt in all the way.

Scheme 154

Note. Replace the vibration damper bolt. Replace O-ring.

Further installation is in reverse order of removal, note the following

Install vibration damper. Refer to VIBRATION DAMPER .

Install ribbed belt. Refer to RIBBED BELT .

CAMSHAFT TIMING CHAIN

Special tools and workshop equipment required

1. Assembly Tool T10352
2. Counter Hold Tool T10355
3. Locking Pin T40011
4. Lever T40243
5. Locking Tool T40267
6. Camshaft Clamp T40271
7. Locking Pin T10060 A

Removing

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Scheme 155

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Scheme 156

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

Scheme 157

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
2. The markings -1- on the camshafts must point upward.

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Press the oil pump chain tensioner in direction of -arrow- and secure it with a T40011.

Scheme 158

Remove the oil pump chain tensioner -1-.

Remove the oil pump chain tensioner.

Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner in direction of -arrow 1-.

Scheme 159

Press the timing chain tensioning rail in direction of -arrow 2- and secure it with the T40011.

Remove the camshaft timing chain from the cylinder head.

Note. The intake camshaft switches in the engine direction of rotation.

Remove the timing chain tensioning rail -2-.

Scheme 160

Remove the guide rail for the camshaft timing chain -1-.

Remove the timing chain.

Installing

1. Tightening specifications, refer to «CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) .

Note. The following must be performed in one sequence. A second technician is required for this. The painted links of the timing chain must be positioned on the markings on the chain sprockets. Hold the wrench tight until the tensioning rail is installed.

Mount the timing chain on the exhaust camshaft.

Mount the timing chain on the crankshaft.

Turn the intake camshaft using the wrench in direction of -arrow- and mount the timing chain.

Scheme 161

Install the timing chain tensioning rail and tighten the bolt -2-.

Install the camshaft timing chain guide rail and tighten the bolts -1-.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011.

Tighten the bearing bracket bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Install the control valve -6- CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Further installation is performed in reverse order of removal, note the following

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

BALANCE SHAFT TIMING CHAIN

Removing

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Remove the camshaft timing chain tensioner -3-.

Remove the balance shaft chain tensioner -1-.

Scheme 162

Remove the tensioning rail -2-.

Remove the guide rail -3-.

Remove the guide rail -4-.

Remove the timing chain.

Installing

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) .

Turn the intermediate shaft sprocket/balance shaft to the marking -arrow-.

Note. The painted links of the timing chain must be positioned on the markings on the chain sprockets.

Mount the timing chain; the painted links of the timing chain must be positioned on the markings on the chain sprockets.

Scheme 163

Install the timing chain guide rail and tighten the bolts -4-.

Install the timing chain guide rail and tighten the bolts -3-.

Install the timing chain tensioning rail and tighten the bolt -2-.

Insert the timing chain tensioner -1- with locking compound.

Check the setting one more time.

Check the markings on the intermediate shaft sprocket/balance shaft -arrow-.

Note. The marking on the intermediate shaft sprocket/balance shaft is shown with the chain removed.

The rest of the installation is in reverse order of removal, note the following

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

BALANCE SHAFT FOR INTAKE SIDE

Special tools and workshop equipment required

1. Puller T10394
2. Half Shell T10394/1
3. Puller T10055

Removing

Note. The intake camshaft balance shaft must be replaced after removal.

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Remove the intermediate shaft sprocket -1-.

Remove the bolt -2- on the intake camshaft balance shaft.

Scheme 164

Install the half shell T10394/1 from the T10394 and turn it upward in direction of -arrow-.

Scheme 165

Install the puller T10394 and push the sliding sleeve in direction of -arrow-.

Scheme 166

Install the T10055 into the T10394 and remove the balance shaft in direction -of arrow-.

Scheme 167

Installing

Note. Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be inserted into the cylinder block without forcing it in. If this is not the case, then the balance shaft must be installed cooled.

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) .

Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

Lubricate the balance shaft bearing with engine oil.

Install the new intake camshaft shim and tighten the bolt -2-.

Replace the O-ring -1- and coat with engine oil.

Coat the mounting pin with engine oil and insert it. The alignment pin -arrow- for the mounting pin must engage in the hole in the cylinder block.

Mark the tooth face on the intermediate shaft sprocket with paint -arrows-.

Scheme 168

Install the intermediate shaft sprocket. The marking on the balance shaft must be between the markings on the tooth faces.

Tighten the bolt -1- for the intermediate shaft sprocket: tightening sequence BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Check the markings on the intermediate shaft sprocket/balance shaft -arrow-.

Note. Due to the ratio, the marking align only every 7th turn.

Further installation is in reverse order of removal, note the following

Install the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

Replace the coolant pump drive seal. Refer to COOLANT PUMP DRIVE SHAFT SEAL .

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

EXHAUST SIDE BALANCE SHAFT

Special tools and workshop equipment required

1. Puller T10394
2. Half Shell T10394/1
3. Puller T10055

Removing

Note. The exhaust camshaft balance shaft must be replaced after removal.

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Remove the bolt -1- on the exhaust camshaft balance shaft.

Install the half shell T10394/1 from the T10394.

Scheme 169

Install the T10394 and push the sliding sleeve in direction of -arrow-.

Scheme 170

Install the T10055 into the T10394 and remove the balance shaft.

Scheme 171

Installing

Note. Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be inserted into the cylinder block without forcing it in. If this is not the case, then the balance shaft must be installed cooled.

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta) .

Check the installation position of the pipe for the balance shaft -arrow-.

The pin -arrow- must engage in the groove.

Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

Lubricate the balance shaft bearing with engine oil.

Before tightening the bolt -1- make sure the balance shaft lies level on the crankshaft.

Note. If the balance shaft is not level, then the pipe for the balance shaft must be installed again.

The rest of the assembly is basically a reverse of the disassembling sequence. When doing this note the following

Install the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Assembly Tool T10352 and Assembly Tool T10352/1
3. Counter Holder Tool T10355
4. Locking Pin T40011
5. Engine Bung Set VAS 6122
6. Polydrive Bit and Drive Socket T10070
7. Lever T40243
8. Camshaft locator T40271
9. Locking Tool T40267

Removing

Note. During installation, cable ties must be installed at the same location. Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.

Remove the engine cover -arrows-.

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Scheme 172

Unclip the lower air guide, to do so disengage the clips -arrows-.

Scheme 173

Remove the lower air guide together with the air guide hose.

Disconnect electrical connector -1- on mass air flow (MAF) sensor -G70-.

Scheme 174

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore - 3-.

Loosen the hose clamp -2-.

Scheme 175

Remove bolt -4-.

Disconnect the connector -arrow- and free up the wire.

Note. Ignore -1 and 3-.

Open coolant reservoir cap.

Remove front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

Remove the right front wheel.

Remove noise insulation. Refer to Removal and Installation .

Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Cabriolet

Remove the noise insulation bracket. Refer to Removal and Installation .

All

Remove the air guide pipe -1 and 2-.

Scheme 176

Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -2, 3, 4 and arrow-.

Remove bolts -arrows-.

Remove the air guide pipe by lifting the clamps -1 and 2-.

Disconnect the connectors -1 and 2- and free up the wire -arrows-.

Scheme 177

Remove bolts -1 and 2- and remove the turbocharger support.

Scheme 178

Remove the banjo bolt -2- and move the coolant line to the side.

Scheme 179

Remove the bolts -1- on the oil return line.

Remove the bolt -3- on the oil supply line.

Note. The installation location is shown with the engine removed.

Press the release buttons, remove the air guide hose -2- and move them to the side.

Scheme 180

Remove the air guide pipe bolts -arrows-.

Lay aside the air guide pipe with the connected crankcase ventilation hose -1-. Loosen the hose clamp -3- to do so.

All

Disconnect the oil supply line from the turbocharger -1-.

Scheme 181

Disconnect the electrical connectors -arrows- on ignition coils.

Remove the ignition coils with the T40039.

Disconnect the crankcase ventilation hoses -1 and 2-.

Scheme 182

Remove the bolts -arrows- and remove the crankcase ventilation.

Remove the vacuum hose from the vacuum pump -1- and free it up.

Scheme 183

Remove Ground (GND) wire -2-.

Disconnect the connector -3- and free up the wiring harness.

Remove the coolant hoses -4 and 5-.

Disconnect the connector -A- and hose -B- from the secondary air injection (AIR) solenoid valve -N112-.

Scheme 184

Loosen the coolant pipe; remove the bolts -arrows-.

Scheme 185

Remove the coolant hoses on the rear of the cylinder head.

Disconnect the connectors -1 through 4-.

Scheme 186

Free up the electrical cable -5-.

Disconnect the vacuum hose -6- leading to the EVAP filter.

Disconnect the electrical connectors -1 - and pull the connectors out of the retainer.

Scheme 187

Disconnect the connectors -2 through 4-.

Remove the vacuum line -5-.

Disconnect the coolant line from the intake manifold, when doing this, remove the bolts -arrows-.

Scheme 188

Remove the intake manifold bracket by removing the mounting nut -1- and bolt -2-.

Scheme 189

Remove the oil filter.

Disconnect fuel supply hose -2- by pressing release ring.

Scheme 190

Disconnect the vacuum line -1- to the EVAP canister by pressing the release button.

Remove the coolant hose -3-.

Pull the EVAP canister up out of the bracket -arrow- and place it on the engine.

Scheme 191

Disconnect the coolant hoses -arrows- and free them up.

Scheme 192

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Remove the bolts -1 through 5- and remove the timing chain upper cover.

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Mark the drive chain on the chain sprocket -arrows- with a waterproof marker.

Scheme 193

Remove the plug -arrow-.

Scheme 194

Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner in direction of -arrow 1-.

Scheme 195

Turn the crankshaft opposite the engine direction of rotation in direction of -arrow 2- and secure it with a T40011.

Note. The intake camshaft switches in the engine direction of rotation.

Remove the bolt -1- and guide the tensioning rail -2- downward.

Scheme 196

Remove the upper guide track -3- by unlocking the latch with a screwdriver and pushing the guide track forward.

Remove camshaft timing chain from chain sprockets.

Turn the sealing plug -arrows- counterclockwise 90° in direction of -arrow- and remove it.

Scheme 197

Remove the ball head -1 through 2-.

Remove the cap.

Remove the bolts -arrows-.

Remove the cylinder head bolts with the polydrive bit and drive socket T10070 in the following sequence: -1 through 5-.

Note. To remove the cylinder head bolts, turn the camshaft with a wrench if necessary. Make sure all wires and cables are disconnected! Pay attention to the tension and guide tracks when lifting the cylinder head.

Remove the cylinder head.

Lay the cylinder head on a soft surface, such as foam.

Installing

1. Tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview) .

Note. Replace bolts which have been tightened to torque. Replace sealing rings, seals and self-locking nuts. Note different sealant for cylinder head sealing surfaces and bolts. Secure all hose connections with hose clamps appropriate for the model. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Set cylinder head gasket in place.

Scheme 198

1. Pay attention to centering pins in cylinder block -arrows-.
2. Cylinder head gasket installed position: the part number must be readable from the intake side.

If the crankshaft was turned in the meanwhile: bring the piston for cylinder 1 to TDC and then turn the crankshaft back just a little.

Set cylinder head in place.

Insert cylinder head bolts and tighten by hand.

Note. In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.

Cylinder head tightening sequence CYLINDER HEAD ASSEMBLY OVERVIEW

Note. There is no requirement to tighten the cylinder head bolts after repairs.

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Note. The marked links of the timing chain must be positioned on the markings on the chain sprockets.

Mount the camshaft timing chain: the drive chain/chain sprocket markings -arrows- must align.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011.

Tighten the bearing bracket bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Install the control valve -6- CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Turn the intake camshaft using the wrench in the -direction of the arrow- and mount the timing chain.

Further assembly is in the reverse order of removal, thereby observing the following

Install timing chain upper cover. Refer to UPPER TIMING CHAIN COVER .

Change engine oil. Refer to ENGINE OIL, DRAINING AND REPLACING OIL FILTER and refer to ENGINE OIL, FILLING .

Replace coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Cylinder Head Cover Tightening Sequence

Replace bolts.

Hand-tighten bolts in several stages in -1 to 6- sequence.

Tighten the bolts in a -1 to 6- sequence to 8 Nm using a torque wrench.

Tighten the bolts an additional 90° using a rigid wrench in the sequence -1 to 6-.

Note. Make sure the cylinder head cover is not tilted.

Valve Dimensions

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

CAMSHAFTS

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Assembly Tool T10352 and Assembly Tool T10352/1
3. Counter Holder Tool T10355
4. Locking Pin T40011
5. Thrust Piece T10174

Removing

Note. The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked. The camshaft bearings are integrated in the cylinder head or cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover. If the cylinder head cover was loosened, then the cap must be replaced. During installation, cable ties must be installed at the same location.

Removing

Remove the engine cover -arrows-.

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Unclip the lower air guide, to do so disengage the clips -arrows-.

Remove the lower air guide together with the air guide hose.

Disconnect electrical connector -1- on mass air flow (MAF) sensor -G70-.

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore -3-.

Remove bolts -arrows-.

Remove the air guide pipe by lifting the clamps -1 and 2-.

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Remove the bolts -1 through 5- and remove the timing chain upper cover.

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Mark the drive chain on the chain sprocket -arrows- with a waterproof marker.

Remove the plug -arrow-.

Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner direction of -arrow 1-.

Turn the crankshaft opposite the engine direction of rotation in arrow direction -2- and secure it with a T40011.

Note. The intake camshaft switches in the engine direction of rotation.

Remove the bolt -1- and guide the tensioning rail -2- downward.

Remove the upper guide track -3- by unlocking the latch with a screwdriver and pushing the guide track forward.

Remove camshaft timing chain from chain sprockets.

Disconnect the connector on the ignition coils and free up the wiring harness.

Remove the ignition coils with the T40039.

Disconnect the crankcase ventilation hoses -1 and 2-.

Remove the bolts -arrows- and remove the crankcase ventilation.

Disconnect the lines -1 and 3-.

Scheme 199

Disconnect the electrical connector -2- from the camshaft position (CMP) sensor -G40-.

Remove the high pressure pump. Refer to Removal and Installation .

Remove vacuum pump. Refer to Removal and Installation .

Remove the cylinder head cover bolts in -1 to 6- sequence.

Remove the cylinder head cover.

Remove the camshafts.

Installing

1. Tightening specifications, refer to «VALVETRAIN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__valvetrain-assembly-overview) .

Note. Sealing surfaces must be completely free of oil and grease. The pistons must not be positioned at TDC. Make sure that all roller cam followers make contact correctly on valve stem ends. Note the expiration date of the silicone sealant. The cover must be installed within 5 minutes after the silicone sealant has been applied.

Remove any sealant residue on the cylinder head using the flat blade scraper.

Remove any seal out of the groove in the cylinder head cover as well as from any sealing surface using, for example, a rotating plastic brush.

Clean sealing surfaces, must be free of oil and grease.

Cut tube nozzle at front marking (jet dia. approximately 2 mm).

Lubricate the running surfaces of both camshafts.

Place the camshaft into the cylinder head; the recesses -arrows- must be perpendicular to each other.

Scheme 200

Replace the cylinder head cover bolts.

Apply the silicone sealant on the clean sealing surface of the cylinder head cover as shown in the illustration -arrows-.

Scheme 201

1. Sealant bead thickness: 2 to 3 mm.

Note. The cylinder head cover must be installed within 5 minutes after the silicone sealant has been applied. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube. Note the expiration date of the sealing compound.

Tighten the bolts in several steps, tightening sequence VALVETRAIN ASSEMBLY OVERVIEW .

Note. Make sure the cylinder head cover is not tilted. Drive the cap -1- in without sealing using the T10174. -a- : 1 to 2 mm

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Note. The marked links of the timing chain must be positioned on the markings on the chain sprockets.

Mount the camshaft timing chain: the drive chain/chain sprocket markings -arrows- must align.

Turn the intake camshaft using the wrench in direction of -arrow- and mount the timing chain.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011.

Tighten the bearing bracket bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Install the control valve -6- CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW .

Install the vacuum pump. Refer to Removal and Installation .

Install the high pressure pump. Refer to Removal and Installation .

The rest of the assembly is basically a reverse of the disassembling sequence.

VALVE STEM SEALS, CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Adapter T40012
5. Torque Wrench V.A.G 1331
6. Valve Retainer Disassembly and Assembly Device VAS 5161
7. Guide Plate for 2.0L and 3.0L FSI Engine VAS 5161/19B

Removing.

Remove the camshafts, refer to CAMSHAFTS .

Remove the roller rocker lever and place it on a clean surface. Make sure that roller cam followers are not interchanged.

Remove the spark plugs using a 3122 B.

Tighten the VAS 5161/19B on the cylinder head as shown using the knurled bolts VAS 5161/12.

Scheme 202

Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

Install the T40012 in the spark plug threads.

Scheme 203

Connect compressed air with at least 6 bar pressure.

Loosen stuck valve retainers using a drift VAS 5161/3 and a plastic hammer.

For the intake side

Scheme 204

Install the engaging device VAS 5161/6 with the installation fork VAS 5161/5 in the center threads of the guide plate for FSI engine VAS 5161/19B.

Insert the installation cartridge VAS 5161/8 in the guide plate for FSI engine VAS 5161/19B.

Engage the pressure fork VAS 5161/2 on the engaging device VAS 5161/6.

For the exhaust side

Scheme 205

Install the engaging device VAS 5161/6 with the installation fork VAS 5161/5 in the outer threads of the guide plate for FSI engine VAS 5161/19B.

Press the installation cartridge VAS 5161/8 down while rotating its knurled bolt to the right until the points engage in the valve retainers.

Move the knurled wheel back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

Release the pressure fork VAS 5161/2.

Remove the installation cartridge VAS 5161/8.

Remove valve stem seals using 3364.

Scheme 206

If the 3364 cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Scheme 207

Position the lower section of the 3364 on the valve stem seal.

Scheme 208

Place the drift -1- in the hole in the lower section of the removal tool.

Position the lever on the removal tool and remove the valve stem seal -arrow-.

Installing

Place plastic sleeve -A- on valve stem to prevent damage to new valve stem oil seals -B-.

Scheme 209

Oil the sealing lip of valve stem oil seal -B-, insert into 3365 and carefully slide onto valve guide.

Remove plastic sleeve -A-.

Insert the valve spring and valve spring plate.

Connect the VAS 5161 as illustrated.

For the intake side

For the exhaust side

Note. If the valve retainers were removed from the installation cartridge, they must be inserted into valve insertion device VAS 5161/18 next. Press the installation cartridge VAS 5161/8 onto the insertion device from above and capture the valve retainers.

Install the VAS 5161/8 using the pressure fork VAS 5161/2. Turn the knurled bolt on the installation cartridge back and forth and remove it upward.

Release the VAS 5161/2 with the knurled bolt pulled.

Remove the VAS 5161.

The rest of the assembly is basically a reverse of the disassembling sequence.

Install the camshafts. Refer to CAMSHAFTS .

VALVE STEM SEALS, CYLINDER HEAR REMOVED

Special tools and workshop equipment required

1. Valve Seal Removal Tool 3364
2. Valve Stem Seal Driver 3365
3. Valve Retainer Disassembly and Assembly Device VAS 5161
4. Guide Plate for 2.0L and 3.0L FSI Engine VAS 5161/19B
5. Engine and Transmission Holder VAS 6095
6. Cylinder Head Tension Device VAS 6419

Procedure

Camshafts, removing. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Mount the VAS 6419 into the VAS 6095.

Scheme 210

Tension the cylinder head on the VAS 6419 as illustrated.

Connect the VAS 6419 to the compressed air.

Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seals that will be removed.

Let enough compressed air flow into the air cushion until it contacts the valve plate.

Place the guide plate VAS 5161/19B from the VAS 5161 on the cylinder head.

Secure the guide plate with the knurled screws VAS 5161/12.

Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Scheme 211

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 212

Slide installation cartridge VAS 5161/8 in guide plate.

Intake side

Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Exhaust side

Engage the pressure fork VAS 5161/2 on the engaging device as illustrated.

Scheme 213

Continued for both sides

Press the installation cartridge down with the pressure fork.

At the same time, rotate installation cartridge knurled screw right until points engage in valve retainers.

Move the knurled bolt to the left and right.

1. Valve retainers are pressed against each other and capture in the installation cartridge.

Release pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Remove the valve stem seal with the 3364.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the valve retainer inserting tool VAS 5161/18 next.

Scheme 214

1. The large diameter of the valve retainers point upward.

Press installation cartridge from above onto valve retainer inserting tool and capture retainers.

Insert valve spring and valve spring plate.

Install the guide plate on the cylinder head.

Insert installation cartridge with knurled spacer ring in guide plate.

Press pressure fork down and pull knurled screw up, turning left and right.

1. The valve retainers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Repeat the procedure on each valve.

Assembly is in reverse order of removal, note the following

Install camshafts. Refer to CAMSHAFTS .

Scheme 215

Special tools and workshop equipment required

1. Valve Seal Removal Tool 3364
2. Valve Stem Seal Driver 3365
3. Valve Retainer Disassembly and Assembly Device VAS 5161
4. Guide Plate for 2.0L and 3.0L FSI Engine VAS 5161/19B
5. Engine and Transmission Holder VAS 6095
6. Cylinder Head Tension Device VAS 6419

Scheme 216

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Adapter T40012
5. Torque Wrench V.A.G 1331
6. Valve Retainer Disassembly and Assembly Device VAS 5161
7. Guide Plate for 2.0L and 3.0L FSI Engine VAS 5161/19B

Special tools and workshop equipment required

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

1. Spark Plug Removal Tool 3122 B
2. Ignition Coil Puller T40039
3. Compression Tester V.A.G 1763
4. Dial Gauge Holder VW 387
5. Dial Gauge VAS 6079
6. Torque Wrench V.A.G 1783
7. Locking Pin T10060 A
8. Counter Hold Tool T10355
9. Engine Support Bridge 10 - 222 A with Spindle 10 - 222 A /11
10. Lifting Tackle 2024 A
11. Bits T10099
12. Thrust Piece T10368
13. Thrust Piece T10354
14. Pulling Hook T20143
15. Assembly Tool T10352 and Assembly Tool T10352/1
16. Locking Pin T40011
17. Puller T10394
18. Puller T10055
19. Engine Bung Set VAS 6122
20. Thrust Piece T10174
21. Open End Spanner Insert AF 10 V.A.G 1783/1

See also:
• Removal and Installation
• SPARK PLUGS, REMOVING AND INSTALLING
• IGNITION COILS WITH POWER OUTPUT STAGES
• Removal and Installation
• SUBFRAME ASSEMBLY OVERVIEW
• ENGINE, CHECKING OIL LEVEL
• RIBBED BELT TENSIONER
• RIBBED BELT
• SUBFRAME MOUNT, ADJUSTING
• RIBBED BELT DRIVE ASSEMBLY OVERVIEW
• VIBRATION DAMPER
• COOLANT PUMP TOOTHED BELT
• COOLANT PUMP DRIVE SHAFT SEAL
• FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER
• COOLING SYSTEM, DRAINING AND FILLING
• CLEAN WORKING CONDITIONS
• ENGINE OIL, FILLING
• Removal and Installation
• CAMSHAFT ADJUSTMENT VALVE
• TIMING CHAIN COVER ASSEMBLY OVERVIEW
• LOWER TIMING CHAIN COVER
• VIBRATION DAMPER SHAFT SEAL
• EXHAUST CAMSHAFT BALANCE SHAFT
• INTAKE CAMSHAFT BALANCE SHAFT
• BALANCE SHAFT TIMING CHAIN
• CYLINDER HEAD ASSEMBLY OVERVIEW
• VALVETRAIN ASSEMBLY OVERVIEW
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING
• VALVE STEM SEALS WITH CYLINDER HEAR REMOVED, REPLACING
• CAMSHAFTS
• UPPER TIMING CHAIN COVER
• ENGINE WITH DIAL GAUGE -VAS 6079- AT TDC, POSITIONING
• CAMSHAFT TIMING CHAIN