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2.0l - Cylinder Head, Valvetrain - Engine Code(s): Bpy Audi A3 8P рестайлинг

Mechanical 104 illustrations ~7792 words

TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover 25 and guard is divided in engine bracket area. Vehicles with divided toothed belt guard - assembly overview. Refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.

Scheme 111

Scheme 111: TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW
Scheme 111: TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW
  1. Bolt 10 Nm Insert with locking fluid Locking fluid
  2. Upper Toothed Belt Guard
  3. Bolt Replace 50 Nm plus an additional 180° turn Use retainer 3036 for loosening and tightening (Scheme 112)
  4. Camshaft Sprocket When removing and installing, remove toothed belt, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-without-divided-toothed-belt) Installed position is fixed by woodruff key, refer to 7 Camshaft sprocket, removing (Scheme 113)
  5. Bolt 10 Nm Insert with locking fluid Locking fluid
  6. Rear Toothed Belt Guard
  7. Woodruff Key Make sure it is secure
  8. Nut 25 Nm
  9. Semi-Automatic Tensioning Roller
  10. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__coolant-pump)
  11. O-ring Replace Coat with coolant
  12. Bolt 25 Nm
  13. Damper Roller
  14. Bolt 15 Nm
  15. Bolt 35 Nm
  16. Damper Roller
  17. Sealing Flange Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy__front-sealing-flange)
  18. Toothed Belt Gear Diamond Disc Replace after removing toothed belt gear
  19. Crankshaft Toothed Belt Sprocket There must be no oil on the contact surface between the toothed belt sprocket and crankshaft Only possible to install in one position
  20. Bolt Replace 90 Nm plus an additional 90° turn Do not oil Fastening counter support 3415 (Scheme 114)
  21. Toothed Belt Before removing, mark direction of rotation using chalk or felt-tip marker Check for wear Removing, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-without-divided-toothed-belt) Installing (adjusting valve timing), refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-without-divided-toothed-belt)
  22. Lower Toothed Belt Guard
  23. Engine Support Removing: Toothed belt, removing and installing, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-without-divided-toothed-belt)
  24. Bolt 40 Nm Follow the tightening sequence see scheme 47
  25. Cover for Toothed Belt Guard

Scheme 112

Scheme 112
Scheme 112

When loosening and tightening the center bolt, use retainer 3036.

Scheme 113

Scheme 113
Scheme 113

Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

Scheme 114

Scheme 114
Scheme 114

When loosening and tightening the center bolt, use counter support 3415.

TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover 25 and guard is divided in engine bracket area. Vehicles without divided toothed belt guard - assembly overview. Refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW .

Scheme 115

Scheme 115: TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW
Scheme 115: TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW
  1. Bolt 10 Nm
  2. Upper Toothed Belt Guard
  3. Bolt 50 Nm plus an additional 180° Use retainer 3036 for loosening and tightening see scheme 6
  4. Camshaft Sprocket Installation position secured by woodruff key 7 Camshaft sprocket, removing see scheme 7
  5. Bolt 10 Nm Insert with locking fluid
  6. Rear Toothed Belt Guard
  7. Woodruff Key Make sure it is secure
  8. Bolt 25 Nm
  9. Semi-Automatic Tensioning Roller
  10. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__coolant-pump)
  11. O-ring Replace
  12. Bolt 25 Nm
  13. Damper Roller
  14. Bolt 15 Nm
  15. Bolt 35 Nm
  16. Damper Roller
  17. Sealing Flange Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy__front-sealing-flange)
  18. Diamond Disc Replace
  19. Crankshaft Toothed Belt Sprocket There must be no oil on the contact surface between toothed belt gear, diamond disc and crankshaft Only possible to install in one position
  20. Bolt Replace 90 Nm plus an additional 90° turn Do not oil Use counter support 3415 for loosening and tightening see scheme 8
  21. Toothed Belt Before removing, mark direction of rotation using chalk or felt-tip marker Check for wear Removing and installing, refer to «TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-with-divided-toothed-belt)
  22. Lower Toothed Belt Guard
  23. Bolts 8 Nm 7 pieces For lower toothed belt guard
  24. Engine Mount
  25. Bolt 45 Nm

When loosening and tightening the center bolt, use retainer 3036.

Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

When loosening and tightening the center bolt, use retainer 3415.

CYLINDER HEAD OVERVIEW

Note. Replace the cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. When installing a replacement cylinder head with camshafts installed, contact surfaces between roller rocker lever and cam running surfaces must be oiled. The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

Scheme 116

Scheme 116: CYLINDER HEAD OVERVIEW
Scheme 116: CYLINDER HEAD OVERVIEW
  1. Bolt Tightening sequence (Scheme 117)
  2. Cylinder Head Cover
  3. Gasket Replace if damaged or leaking
  4. Valve Housing
  5. Oil Filler Cap
  6. Gasket Replace if damaged or leaking
  7. Bolt 4 Nm
  8. Cylinder Head Cover Gasket Replace if damaged or leaking
  9. Vacuum Pump
  10. Bolt 4 Nm
  11. Camshaft Adjustment Valve 1 -N205- Removing, refer to «CAMSHAFT ADJUSTMENT VALVE 1»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__camshaft-adjustment-valve-1)
  12. Seal Replace
  13. Bolt 10 Nm
  14. Cable Bracket
  15. Seal Replace if damaged or leaking
  16. Bolt 10 Nm
  17. Housing
  18. Gasket Replace
  19. Transport Strap
  20. Bolt 25 Nm
  21. Intake Manifold Stud Bolt 10 Nm
  22. Partition Plate
  23. Cylinder Head Gasket Replace Note installation position: The part number faces the cylinder head
  24. Bolt 10 Nm
  25. Camshaft Position Sensor -G40
  26. Seal
  27. Tensioning Roller Stud Bolt 10 Nm
  28. Exhaust Manifold Stud Bolt 20 Nm
  29. Cylinder Head Check for distortion (Scheme 120)
  30. Cylinder Head Bolt Replace Tightening specification: 40 Nm plus an additional 180° turn Observe sequence for loosening (Scheme 118)Observe sequence for tightening (Scheme 119)

Scheme 117

Scheme 117
Scheme 117

Install bolts -1 through 14- and tighten by hand.

Tighten the bolts -1 through 14- diagonally to 10 Nm.

Scheme 118

Scheme 118
Scheme 118

Loosen cylinder head bolts in sequence shown and remove.

Scheme 119

Scheme 119
Scheme 119

Tighten cylinder head bolts in -1 through 10- sequence as follows

1. Tighten to 40 Nm using a torque wrench.

2. Tighten further 90° using a rigid wrench.

3. Tighten further 90° using a rigid wrench.

Scheme 120

Scheme 120
Scheme 120

Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.

  1. Maximum permissible distortion: 0.05 mm.

VALVETRAIN OVERVIEW

Note. The cylinder head and guide frame must be replaced together. Do not start the engine for approximately 30 minutes after installing the camshafts. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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 the gaskets and seals.

Scheme 121

Scheme 121: VALVETRAIN OVERVIEW
Scheme 121: VALVETRAIN OVERVIEW
  1. 1 - Bolt Replace 50 Nm plus an additional 180° turn Use retainer 3036 for loosening and tightening (Scheme 112)
  2. 2 - Camshaft Sprocket
  3. 3 - Seal Removing and installing, refer to «EXHAUST CAMSHAFT SEAL»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__exhaust-camshaft-seal)
  4. 4 - Cylinder Head Reworking dimension (Scheme 122)
  5. 5 - Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valve-guides-checking)
  6. 6 - Valve Stem Seal
  7. 7 - Valve Spring
  8. 8 - Top Valve Spring Retainer Replace, refer to «VALVE STEM SEALS, CYLINDER HEAD INSTALLED»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valve-stem-seals-cylinder-head-installed) or «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valve-stem-seals-with-cylinder-head)
  9. 9 - Valve Retainers
  10. 10 - Hydraulic Valve Play Balancing Element Do not interchange Lubricate contact surface
  11. 11 - Fitted Key Make sure it is secure
  12. 12 - Exhaust Camshaft Check radial clearance using Plastigage (roller rocker lever removed) Radial play with bearing diameter 24 mm: 0.024 to 0.066 mm Radial play with bearing diameter 32 mm: 0.030 to 0.051 mm Run-out: max. 0.04 mm
  13. 13 - Guide Frame With integrated camshaft bearings Clean sealing surface, reworking is not permitted. Remove old sealant residue.
  14. 14 - Bolt Replace Tightening sequence (Scheme 123)
  15. 15 - Camshaft Adjuster
  16. 16 - Bolt Replace 20 Nm plus an additional 45° turn
  17. 17 - Intake Camshaft Check radial clearance using Plastigage (roller rocker lever removed) Radial play with bearing diameter 24 mm: 0.024 to 0.066 mm Run-out: max. 0.04 mm
  18. 18 - Chain Tensioner Removing and installing, refer to «CAMSHAFT ADJUSTER»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__camshaft-adjuster) Before removing, secure with locking pin T10115
  19. 19 - Drive Chain
  20. 20 - Bolt 10 Nm
  21. 21 - Bolt 10 Nm
  22. 22 - Phase Sensor
  23. 23 - Exhaust Valve Do not reface, only lapping is permitted For the correct valve dimensions (Scheme 124)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valve-guides-checking)
  24. 24 - Intake Valve Do not reface, only lapping is permitted For the correct valve dimensions (Scheme 124)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valve-guides-checking)
  25. 25 - Cap Replace Removing: When guide frame is installed: Pierce through one side of the cover with an awl and pry it out Installing: Without sealant, press in 1 to 2 mm using the thrust piece 3334

Scheme 122

Scheme 122
Scheme 122

Resurfacing cylinder head (face grinding) is only permissible to minimum dimension a.

  1. Minimum dimension: a = 139.20 mm

Scheme 123

Scheme 123
Scheme 123

Replace bolts

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

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

Give 90° ( 1 / 4 turn) additional turn in sequence -1 to 6- using rigid wrench.

Note. Ensure guide frame is not tilted.

Scheme 124

Scheme 124
Scheme 124

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

DimensionIntake ValveExhaust Valve
Diameter aMm33.85 ± 0.1028.0 ± 0.1
Diameter bMm5.98 ± 0.015.96 ± 0.01
CMm104.0 ± 0.2101.9 ± 0.2
ΑAngle°4545

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Cable Bracket10
Camshaft Adjuster 120 + 45°
Camshaft Adjustment Valve 14
Camshaft Position Sensor10
Camshaft Sprocket 150 + 180°
Chain Tensioner10
Cylinder Head Bolt40 + 180°
Exhaust Manifold Stud Bolt20
Housing10
Intake Manifold Stud Bolt10
Phase Sensor10
Tensioning Roller Stud Bolt10
Transport Strap25
Valve Housing4
Toothed Belt Drive, with Divided Toothed Belt Guard
Camshaft Sprocket50 Nm + 180°
Coolant Pump15
Crankshaft Toothed Belt Sprocket 190 + 90°
Damper Roller for Rear Toothed Belt Guard25
Damper Roller for Sealing Flange35
Engine Mount45
Lower Toothed Belt Guard8
Rear Toothed Belt Guard 210
Semi-Automatic Tensioning Roller, Nut25
Upper Toothed Belt Guard10
Toothed Belt Drive, without Divided Toothed Belt Guard
Camshaft Sprocket 150 + 180°
Coolant Pump35
Crankshaft Toothed Belt Sprocket 190 + 90°
Damper Roller25
Engine Support40
Rear Toothed Belt Guard 210
Semi-Automatic Tensioning Roller, Nut25
Upper Toothed Belt Guard 210
1 Replace 2 Insert with locking fluid

Cylinder Head Cover Tightening Sequence

Install bolts -1 through 14- and tighten by hand.

Tighten the bolts -1 through 14- diagonally to 10 Nm .

Cylinder Head Tightening Sequence

Tighten cylinder head bolts in -1 through 10- sequence as follows

1. Tighten to 40 Nm using a torque wrench.

2. Tighten further 90° using a rigid wrench.

3. Tighten further 90° using a rigid wrench.

Guide Frame Tightening Sequence

Replace bolts

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

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

3. Give 90° ( 1 / 4 turn) additional turn in sequence -1 to 6- using rigid wrench.

Valve Dimensions

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

DimensionIntake ValveExhaust Valve
Diameter aMm33.85 ± 0.1028.0 ± 0.1
Diameter bMm5.98 ± 0.015.96 ± 0.01
CMm104.0 ± 0.2101.9 ± 0.2
ΑAngle°4545

COMPRESSION, CHECKING

Special tools and workshop equipment required

  1. Compression Tester V.A.G 1763
  2. Spark Plug Removal Tool 3122 B
  3. Ignition Coil Puller T40039
  4. Spring Type Clip Pliers VAS 5024 A

Test Sequence

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

Remove the engine cover and air filter. Refer to Removal and Installation .

Remove the ignition coils with power output stage. Refer to REMOVAL AND INSTALLATION .

Remove spark plugs, using the 3122 B.

Disconnect 8-pin connector from fuel injectors. Refer to Removal and Installation

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

Note. Using tester see operating instructions.

Operate starter until tester shows no further pressure increase.

Compression Pressure

New Bar Positive PressureWear Limit Bar Positive PressureDifference Between Cylinders Bar Positive Pressure
11.0 to 14.07.0Max. 3.0

Install sparks plugs.

Install ignition coils with power output stage. Refer to REMOVAL AND INSTALLATION .

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

Read out the DTC memory of engine control module (ECM).

CAMSHAFTS, CHECKING AXIAL CLEARANCE

Special tools and workshop equipment required

  1. Dial Gauge Holder VW 387
  2. Dial Gauge 0-10 mm VAS 6079

Test Sequence

Perform measurement with guide frame removed.

Place camshaft to be checked in guide frame.

Secure the VAS 6079 to cylinder head with the VW 387.

Scheme 125

Scheme 125
Scheme 125

Press camshaft against dial gauge by hand.

Set dial gauge to "0".

Press camshaft off dial gauge and read the value

  1. Axial clearance: 0.05 to 0.17 mm.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

  1. Dial Gauge Holder VW 387
  2. Dial Gauge 0-10 mm 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.

Scheme 126

Scheme 126
Scheme 126

Determine tip clearance.

Wear Limit

Intake Valve GuideExhaust Valve Guide
0.80 mm0.80 mm

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.

TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover 25 and guard is divided in engine bracket area. Toothed belt, vehicles with divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

  1. Engine Support Bridge 10 - 222 A
  2. Shackle (1 Set=2 Pieces) 10 - 222 A /12
  3. Toothed Belt Tensioner T10020
  4. Locking Pin T10060A

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

WARNINGCover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

Open cap of coolant expansion tank.

Remove noise insulation. Refer to Removal and Installation .

Remove right noise insulation fasteners -1 to 3-.

Scheme 127

Scheme 127
Scheme 127

Remove the bolts -1 to 3- and the pendulum support.

Scheme 128

Scheme 128
Scheme 128

Remove the bolts -arrows- and disconnect charge air pipe with hoses.

Scheme 129

Scheme 129
Scheme 129

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

WARNINGThe fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.

Mark the fuel line -1- and the EVAP line -2-.

Scheme 130

Scheme 130
Scheme 130

Disconnect fuel line -1-.

Disconnect the EVAP line -2-.

Disconnect the EVAP line to fuel tank -3-.

Remove EVAP canister upward in direction of -arrow-.

Loosen the coolant hose from the retainer -1-.

Scheme 131

Scheme 131
Scheme 131

Remove bracket for EVAP filter -arrows-.

Remove the filler tube bolt -1- for the windshield washer fluid reservoir.

Scheme 132

Scheme 132
Scheme 132

Remove the retaining clip, by removing bolts -2 and 3-.

Disconnect the electrical connector -1- from coolant level indicator.

Scheme 133

Scheme 133
Scheme 133

Remove coolant expansion tank -arrows-.

Disconnect coolant pipe -arrow-.

Scheme 134

Scheme 134
Scheme 134

Remove ribbed belt and remove the T10060A. Refer to RIBBED BELT .

Install the 10 - 222 A onto fender bolting edge. The spindles are positioned forward.

Scheme 135

Scheme 135
Scheme 135

Hook the carabiner hooks of the spindles with the 10 - 222 A /12 into the lifting eyes.

Remove bolts from assembly mount/engine support -arrows- remove assembly mount completely.

Scheme 136

Scheme 136
Scheme 136
CAUTIONWhen lifting the engine with the 10-222A, make sure that no components/hoses are damaged, overstressed or torn off.

Raise the engine with the 10-222A until both engine support upper bolts -1 and 2- can be loosened and removed.

Scheme 137

Scheme 137
Scheme 137

Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

Scheme 138

Scheme 138
Scheme 138

Remove vibration damper/belt pulley.

Scheme 139

Scheme 139
Scheme 139

Remove the bolts from the lower section of the toothed belt guard -arrows-.

Scheme 140

Scheme 140
Scheme 140

Loosen the lower bolt -3- and remove the engine support downward and out.

Remove remaining bolts from toothed belt guard -arrows- and remove toothed belt guard from engine.

Scheme 141

Scheme 141
Scheme 141

Mark rotational direction of toothed belt.

Loosen tensioning roller and remove toothed belt.

Then, turn the crankshaft back slightly.

Installing

  1. For the correct tightening specifications, refer to «TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-drive-without-divided-toothed)

Note. When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged. The engine must be no more than warm to touch.

Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

Secure the lower toothed belt guard with the two lower bolts.

Install vibration damper/belt pulley with new bolts.

Set the crankshaft and camshaft to TDC at cylinder 1 -arrows-.

Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley -arrow-.

Scheme 142

Scheme 142
Scheme 142

Note. Be sure tensioning roller is properly seated in cylinder head.

Tension toothed belt. To do this by turning the hex key at the eccentric toward the right (in direction of -arrow-) until the notch is positioned above the tab.

Scheme 143

Scheme 143
Scheme 143

Release tension on toothed belt again.

Now tension toothed belt until notch and tab align.

Tighten mounting nut.

Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this it is necessary that the last 45° ( 1 / 8 rotation) is turned without interruption.

Check tension of toothed belt again. Specified value: Tab and notch align.

Check the valve timing again.

If the markings do not match

Repeat valve timing adjustment.

If the markings match

Install the toothed belt guard -arrows-.

Scheme 144

Scheme 144
Scheme 144

Note. Note different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Insert lower bolt -3- into engine support.

Install the engine support from below onto the cylinder block and hand-tighten the bolt.

Raise the engine with the 10-222A until both upper bolts -1 and 2- can be installed.

Tighten all bolts.

Lower engine to installation position.

Fasten engine assembly mount to engine support -arrows-, bringing the contact surfaces into contact using the 10-222A.

Remove the 10-222A.

Connect fuel hoses to connections. Make sure connector couplings are securely fastened.

Install coolant expansion tank.

Connect battery. Refer to REMOVAL AND INSTALLATION

Install the engine cover.

Install the crankshaft belt pulley. Refer to VIBRATION DAMPER .

Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

Install the ribbed belt. Refer to RIBBED BELT .

Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .

Install fuel system. Refer to Removal and Installation .

Install noise insulation pan.

TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover 25 and guard is divided in engine bracket area. Toothed belt, vehicles without divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

  1. Engine Support Bridge 10 - 222 A
  2. Shackle (1 Set=2 Pieces) 10 - 222 A /12
  3. Toothed Belt Tensioner T10020
  4. Locking Pin T10060A

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

WARNINGCover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

Open cap of coolant expansion tank.

Remove noise insulation. Refer to Removal and Installation .

Remove right noise insulation fasteners -1 to 3-.

Remove the bolts -1 to 3- and the pendulum support.

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

WARNINGThe fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.

Mark the fuel line -1- and the EVAP line -2-.

Disconnect fuel line -1-.

Disconnect the EVAP line -2-.

Disconnect the EVAP line to fuel tank -3-.

Remove EVAP canister upward in direction of -arrow-.

Loosen the coolant hose from the retainer -1-.

Remove bracket for EVAP filter -arrows-.

Remove the filler tube bolt for the windshield washer fluid reservoir -1-.

Remove the retaining clip, by removing bolts -2 and 3-.

Disconnect the electrical connector -1- from coolant level indicator.

Remove coolant expansion tank -arrows-.

Disconnect coolant pipe -arrow-.

Scheme 145

Scheme 145
Scheme 145

Remove the ribbed belt. Refer to RIBBED BELT .

Remove ribbed belt tensioner -arrows-.

Scheme 146

Scheme 146
Scheme 146

Loosen coolant pipe -arrows-.

Scheme 147

Scheme 147
Scheme 147

Remove the bolts -arrows- and the toothed belt guard.

Scheme 148

Scheme 148
Scheme 148

Install the 10 - 222 A onto fender bolting edge. The spindles are positioned forward.

Hook the carabiner hooks of the spindles with the 10 - 222 A /12 into the lifting eyes.

Remove bolts from assembly mount/engine support -arrows- remove assembly mount completely.

CAUTIONWhen lifting the engine with the 10-222A, make sure that no components/hoses are damaged, overstressed or torn off.

Raise the engine with the 10-222A until both engine support upper bolts -1 and 2- can be loosened and removed.

Remove the bolts -arrows- and disconnect charge air pipe with hoses.

Loosen the lower bolts -3- and remove the engine support downward and out.

Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

Scheme 149

Scheme 149
Scheme 149

Remove vibration damper/belt pulley.

Note. The TDC markings must align before removing vibration damper. Crankshaft must not be rotated any more until TDC position is marked with an assisting mark.

Remove lower bolts from lower section of toothed belt guard -arrows-.

Scheme 150

Scheme 150
Scheme 150

Identify TDC position -arrow-.

Scheme 151

Scheme 151
Scheme 151

Remove both upper bolts from toothed belt guard -arrows- and remove guard downward from engine.

Scheme 152

Scheme 152
Scheme 152

Now remove engine bracket upward from engine.

Mark rotational direction of toothed belt.

Loosen tensioning roller and remove toothed belt.

Then, turn the crankshaft back slightly.

Installing

  1. For the correct tightening specifications, refer to «TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__toothed-belt-drive-with-divided-toothed) .

Note. When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged. The engine must be no more than warm to the touch.

Position camshaft and crankshaft on TDC marking.

Scheme 153

Scheme 153
Scheme 153

Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley -arrow-.

Note. Be sure tensioning roller is properly seated in cylinder head.

Tension toothed belt. To do so, turn socket head wrench on eccentric clockwise in direction of -arrow- until notch stands above the tab (toothed belt excessively tensioned).

Release tension on toothed belt again.

Now tension toothed belt until notch and tab align.

Tighten mounting nut.

Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this it is necessary that the last 45° ( 1 / 8 rotation) is turned without interruption.

Check toothed belt tension. Specified value: Tab and notch align.

Check valve timing. The markings must align -arrows-.

If the markings do not match

Repeat valve timing adjustment.

If the markings match

Install engine bracket on cylinder block and tighten bolts hand-tight.

Note. Note different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Lower the engine using the 10-222A until lower bolt -3- can be tightened.

Tighten all bolts.

Install engine mounting.

Tighten engine subframe mount and engine bracket bolts hand-tight -arrows-, by bringing the contact surfaces into contact using 10 - 222 A.

Remove the 10 - 222 A.

Reconnect fuel and ventilation lines. Make sure connector couplings are securely fastened.

Install coolant expansion tank.

Install the crankshaft belt pulley. Refer to VIBRATION DAMPER .

Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

Install the ribbed belt. Refer to RIBBED BELT .

Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .

Install fuel system. Refer to Removal and Installation .

Install noise insulation. Refer to Removal and Installation .

Install engine cover/air filter.

CAMSHAFT ADJUSTMENT VALVE 1

Special tools and workshop equipment required

  1. Torque Wrench 5-60 Nm V.A.G 1783
  2. Torx® Bit Set V.A.G 1766
  3. Ratchet Insert 1/4" VAS 6234
  4. Spring Type Clip Pliers VAS 5024 A

Removing

Note. Always replace gaskets and seals.

Remove the engine cover and air filter. Refer to Removal and Installation .

Separate electrical connector -1-.

Scheme 154

Scheme 154
Scheme 154

Disengage wiring harness -2- from bracket.

Remove the bolt -3-.

Note. Do not pull out the camshaft adjustment valve 1 -N205- at connector.

Remove bolts -arrows- and remove camshaft adjustment valve 1 from housing.

Scheme 155

Scheme 155
Scheme 155

Installing

  1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__cylinder-head-overview) .

Note. Camshaft adjustment valve 1 as well as housing must be free of dirt and contamination. Remove the new camshaft adjustment valve 1 from packaging only prior to installation.

CAUTIONThe camshaft adjustment valve 1 must not experience any hits or impacts.

Coat sealing ring with engine oil.

Carefully insert camshaft adjustment valve 1 into housing and press it in perpendicular to valve axle by hand as far as stop.

Install bolts and tighten to 4 Nm with the V.A.G 1783, VAS 6234, Torx® bit T20 and bit holder from V.A.G 1766.

Assemble in reverse order of disassembly.

CYLINDER HEAD COVER

Removing

Special tools and workshop equipment required

  1. Ignition Coil Puller T40039
  2. Spring Type Clip Pliers VAS 5024 A

Remove the engine cover and air filter. Refer to Removal and Installation .

Remove the bolts -arrows-.

Remove the ignition coils with power output stage. Refer to Removal and Installation .

Disconnect the EVAP line from the cylinder head cover -1-.

Scheme 156

Scheme 156
Scheme 156

Remove valve housing from cylinder head cover -arrows-.

Remove crankcase ventilation line with heat shield from turbocharger -1-.

Scheme 157

Scheme 157
Scheme 157

Disconnect EVAP line to turbocharger from the cylinder head cover -2-.

Loosen the cylinder head cover starting from the outside and working toward the inside.

Remove the cylinder head cover.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__cylinder-head-overview)

Note. Replace the cylinder head cover gaskets if they are damaged.

Tighten cylinder head cover from inside toward outside.

Make sure the upper toothed belt guard is installed correctly.

Install ignition coils with power output stage. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Drip Tray VAS 6208
  2. Retainer 3036
  3. Puller T40001
  4. Ignition Coil Puller T40039
  5. Hose Clip Pliers V.A.G 1921
  6. Engine Support Bridge 10 - 222 A
  7. Shackle (1 Set=2 Pieces) 10 - 222 A /12
  8. Locking Pin T10060A
  9. Toothed Belt Tensioner T10020
  10. Polydrive Bit and Drive Socket T10070
  11. Engine Bung Set VAS 6122

Removing

  1. Engine installed.

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Change the engine oil if it is dirty. When using sealant, observe the current descriptions

Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.

Remove the engine cover and air filter. Refer to Removal and Installation .

WARNINGCover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

Open cap of coolant expansion tank.

Remove noise insulation. Refer to Removal and Installation .

Remove the right noise insulation - fasteners -1 to 3-.

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

Pry off the caps on the wiper arms with a screwdriver and remove the nuts.

Pull off and remove wiper arms from wiper axles.

Unclip the spray nozzles -arrow-.

Scheme 158

Scheme 158
Scheme 158

Push the spray nozzles, with lines still attached, back through the opening and into the plenum chamber.

Remove rubber seal -1- for plenum chamber cover.

Scheme 159

Scheme 159
Scheme 159

Remove the plenum chamber cover -2-.

Free up the rear engine wiring harness at the partition for plenum chamber.

Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.

Scheme 160

Scheme 160
Scheme 160

Remove partition for plenum chamber -arrows-.

Scheme 161

Scheme 161
Scheme 161

Disconnect the coolant line to coolant expansion tank -arrow-.

Scheme 162

Scheme 162
Scheme 162

Disconnect coolant hose -1-.

Scheme 163

Scheme 163
Scheme 163

Disconnect coolant hose -2-.

Remove ground (GND) wire bolt -1-.

Scheme 164

Scheme 164
Scheme 164

Separate electrical connector -2-.

Disconnect coolant hoses -arrows-.

Remove the intake manifold. Refer to Removal and Installation .

Remove catalytic converter with front exhaust pipe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

Remove right drive axle. Refer to Removal and Installation .

Remove the right drive axle heat shield -arrows-.

Scheme 165

Scheme 165
Scheme 165

Disconnect air guide pipe -arrow- from charge air cooler.

Scheme 166

Scheme 166
Scheme 166

Unfasten air duct from turbocharger -arrows-.

Scheme 167

Scheme 167
Scheme 167

Disconnect the connectors -1 and 2- and free up the cable.

Remove bolts -arrows- and remove air guide pipe.

Note. The illustration depicts the engine removed from behind.

Unfasten turbocharger oil supply line at cylinder block -1-.

Scheme 168

Scheme 168
Scheme 168

Remove turbocharger oil supply line -2-.

Unfasten turbocharger coolant supply line at cylinder block -1-.

Scheme 169

Scheme 169
Scheme 169

Remove coolant supply line to turbocharger -2-.

Remove the coolant supply line for turbocharger -3- at the cylinder block.

Disconnect oil return line -arrows- on turbocharger.

Scheme 170

Scheme 170
Scheme 170

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

Scheme 171

Scheme 171
Scheme 171

Loosen the bolt for camshaft sprocket using the 3036.

Pull off the camshaft sprocket using the T40001 and claws T40001/6 and T40001/7.

Remove the rear toothed belt guard -arrows- from cylinder head.

Scheme 172

Scheme 172
Scheme 172

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Loosen the cylinder head bolts using a T10070, paying attention to the sequence of the cylinder head bolts.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected.

Remove cylinder head.

Cylinder Head, Installing

  1. Tightening specifications and tightening sequence, refer to «CYLINDER HEAD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__cylinder-head-overview)
  2. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(/audi/a3/8p-2004-2008/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy)

Note. Replace the cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. Secure all hose connections using hose clamps of series-production status Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Hot bolt paste

WARNINGOnly turn over the engine at the crankshaft in direction of engine rotation (clockwise).

Note. Turning over the engine is performed at the center bolt of the crankshaft.

Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts -arrows- now face toward each other vertically.

Scheme 173

Scheme 173
Scheme 173

In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.

Set cylinder head gasket in place.

Scheme 174

Scheme 174
Scheme 174
  1. Pay attention to alignment pins -arrows- in cylinder block.
  2. Observe cylinder head seal location, identification: Replacement part number must be visible from intake side.

Set cylinder head in place.

Insert cylinder head bolts and tighten by hand.

Cylinder head tightening sequence TURBOCHARGER OVERVIEW

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

Install cylinder head cover. Refer to CYLINDER HEAD .

Install wiper arm. Refer to Removal and Installation .

Install the ribbed belt. Refer to RIBBED BELT .

Electrical connections and routing. Refer to appropriate SYSTEMS WIRING DIAGRAM.

Install the intake manifold. Refer to Removal and Installation .

Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .

Connect the battery. Refer to Removal and Installation .

Install fuel system. Refer to Removal and Installation .

Check oil level.

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant may not be used again.

WARNINGDo not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

CAMSHAFT ADJUSTER

Special tools and workshop equipment required

  1. Socket T40080
  2. Camshaft Clamp T10252
  3. Toothed Belt Tensioner T10020
  4. Locking Pin T10115

Removing

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

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove the vacuum pump.

Remove camshaft adjuster housing -arrows-.

Scheme 175

Scheme 175
Scheme 175

Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts -arrows- now face toward each other vertically.

Install the T10252 -arrows- as shown and secure.

Scheme 176

Scheme 176
Scheme 176

Loosen mounting bolt from camshaft adjuster using the T40080.

Compress chain tensioner -arrow A- and secure it using the T10115 -arrow B-.

Scheme 177

Scheme 177
Scheme 177

Remove the bolt from the camshaft adjuster and then remove the adjuster and the chain.

Installing

  1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valvetrain-overview) .
  2. For the correct tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__cylinder-head-overview) .
  1. The camshafts must be fixed in place with the T10252.

Place chain on to camshaft adjuster.

Hold camshaft adjuster in front of exhaust camshaft so that notch -A- and pin -B- align.

Scheme 178

Scheme 178
Scheme 178

Place chain in this position on to the intake camshaft chain sprocket, first at top -arrow-.

Scheme 179

Scheme 179
Scheme 179

Slowly turn the intake camshaft with the T10020 in direction of -arrow A- until the camshaft adjuster fits onto the camshaft.

Scheme 180

Scheme 180
Scheme 180

Note. If the pin does not fit into notch: Remove chain and place the chain on again.

Replace camshaft adjuster mounting bolt.

Tighten camshaft adjuster bolt. To do this, use the T40080.

Remove the T10115 -arrow B-.

Assemble in reverse order of disassembly.

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Install high pressure pump. Refer to Removal and Installation .

Install vacuum pump. Refer to Removal and Installation .

CAMSHAFTS

Special tools and workshop equipment required

  1. Puller T40001
  2. Retainer 3036
  3. Camshaft Clamp T10252
  4. Thrust Piece 3334

Removing

Note. Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked. Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, tension on toothed belt must be released. If guide frame was loosened, camshaft sealing ring and sealing cap must be replaced.

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Loosen camshaft gear with the 3036.

Scheme 181

Scheme 181
Scheme 181

Pull off camshaft gear using T40001, claw T40001/6 and claw T40001/7.

Remove toothed belt guard at rear of cylinder head.

Remove guide frame bolts in sequence -6 to 1- and carefully remove guide frame.

Remove camshafts together with drive chain from cylinder head.

Prevent dirt and adhesive residue from entering cylinder head.

Installing

  1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valvetrain-overview) .
  2. For the correct tightening specifications, refer to «CYLINDER HEAD OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__cylinder-head-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.

Remove the old sealant from the guide frame groove and from sealing surfaces.

Scheme 182

Scheme 182
Scheme 182

Prevent dirt and adhesive residue from entering cylinder head.

Oil journal surfaces of camshafts.

Place the drive chain onto the removed camshaft chain sprockets as follows

Oil journal surfaces of camshafts.

Scheme 183

Scheme 183
Scheme 183
  1. Cams -A- of cylinder 4 must face each other.
  2. The notches -arrows- on both camshafts must align.
  3. The side surfaces of the notches must be exactly vertical.

Place camshafts together with drive chain in cylinder head and in chain tensioner.

Verify TDC position of camshafts again.

Scheme 184

Scheme 184
Scheme 184
  1. Cams -A- of cylinder 4 must face each other.
  2. The notches -arrows- on both camshafts must align.
  3. The side surfaces of the notches must be exactly perpendicular to the cylinder head.

Oil journal surfaces of camshafts.

Apply an even, light sealant bead into the clean groove of the guide frame.

Sealant

Note. Sealant must not be applied too thick. Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces. Note the expiration date of the sealing compound.

Set the guide frame in place so that it can get by the EGR vacuum regulator solenoid valve -N18- -arrow-.

Scheme 185

Scheme 185
Scheme 185

Replace guide frame bolts.

Gently tighten bolts from inside working toward outside in several stages.

Tighten bolts in several stages in tightening sequence. (Scheme 123)

Note. Ensure guide frame is not tilted.

Then check TDC position of camshafts by inserting the -T10252- as far as stop.

Note. Rotate camshafts back and forth slightly if necessary to insert the -T10252-. Ignore -arrows-.

If the -T10252- cannot be inserted, remove guide frame again and repeat camshaft installation see scheme 116.

Remove the -T10252-.

Drive in the sealing cap 25 with the 3334 approximately 1 to 2 mm deep.

Install camshaft sealing ring. Refer to EXHAUST CAMSHAFT SEAL .

Install the rear toothed belt guard.

Insert fitting key into camshaft.

Install the camshaft sprocket. Hold the camshaft sprocket with the 3036 and tighten the bolt

Note. When turning camshaft, pistons may not be at TDC for any cylinder. Valves/pistons may be damaged. Be sure fitting keys are properly seated.

Install camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Assemble in reverse order of disassembly.

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 5-50 Nm V.A.G 1331
  6. Valve Cotters Asm/Dis-Asm Device VAS 5161
  7. Guide Plate for FSI Engine VAS 5161/19B
  8. 2 Knurled Thumb Screws VAS 5161/12

Valve Stem Seals, Removing

Remove the camshafts. Refer to CAMSHAFTS .

Note. To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR vacuum regulator solenoid valve -N18- must also be removed.

Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.

Remove the spark plugs with the 3122 B.

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

Scheme 186

Scheme 186
Scheme 186

Adjust piston of the respective cylinder to "bottom dead center".

Install the T40012 into the spark plug thread and connect compressed air (minimum 6 bar).

Scheme 187

Scheme 187
Scheme 187

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

For the Intake Side

Install the engaging device VAS 5161/6 with the VAS 5161/5 in the center threads of the VAS 5161/19B.

Scheme 188

Scheme 188
Scheme 188

Insert the installation cartridge VAS 5161/8 in the VAS 5161/19B.

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

For the Exhaust Side

Install the engaging device VAS 5161/6 with the installation fork VAS 5161/5 in the outer threads of the VAS 5161/19B.

Scheme 189

Scheme 189
Scheme 189

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 the 3364.

Scheme 190

Scheme 190
Scheme 190

In the event the 3364 cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve -arrow- using a drift and remove impact device.

Scheme 191

Scheme 191
Scheme 191

Place the lower part of the 3364 onto the valve stem seal.

Scheme 192

Scheme 192
Scheme 192

Insert a drift -1- into bore in lower part of extractor device.

Place a lever at the removal tool and pull out the valve stem seal -arrow-.

Valve Stem Seals, Installing

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

Scheme 193

Scheme 193
Scheme 193

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

Remove the plastic sleeve -A-.

Insert valve spring and valve spring retainer.

Install the VAS 5161 as shown.

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

Press down the installation cartridge VAS 5161/8 with the pressure fork VAS 5161/2 and turn the knurled screw of the installation cartridge back and forth while pulling it upward at the same time.

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

Remove the VAS 5161.

Assemble in reverse order of disassembly.

Install the camshafts. Refer to CAMSHAFTS .

VALVE STEM SEALS WITH CYLINDER HEAD REMOVED

Special tools and workshop equipment required

  1. Valve Seal Removal Tool 3364
  2. Valve Stem Seal Driver 3365
  3. Valve Cotters Asm/Dis-Asm Device VAS 5161
  4. Guide Plate for FSI Engine VAS 5161/19B
  5. Engine and Transmission Holder VAS 6095
  6. Cylinder Head Tensioning Device VAS 6419

Procedure

Remove the camshafts. 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 194

Scheme 194
Scheme 194

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 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 keepers with a plastic mallet.

Scheme 195

Scheme 195
Scheme 195

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

Scheme 196

Scheme 196
Scheme 196

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 197

Scheme 197
Scheme 197

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 keeper are pressed against each other and capture in the installation cartridge.

Release the pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

CAUTIONRisk of damage when installing valve stem seals. Place plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

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 5161/18l next.

Scheme 198

Scheme 198
Scheme 198
  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 keepers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Repeat the procedure on each valve.

Assemble in reverse order of disassembling. Note the following

Install the camshafts. Refer to CAMSHAFTS .

EXHAUST CAMSHAFT SEAL

Special tools and workshop equipment required

  1. Seal Puller - General Usage 2085
  2. Retainer 3036
  3. Assembly Tool T10071
  4. Puller T40001
  5. Engine Support Bridge 10 - 222 A
  6. Shackle (1 Set=2 Pieces) 10 - 222 A /12
  7. Toothed Belt Tensioner T10020
  8. Locking Pin T10060A

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

WARNINGCover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

Open cap of coolant expansion tank.

Remove noise insulation. Refer to Removal and Installation .

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

Loosen camshaft sprocket, using 3036.

Pull off the camshaft sprocket using the T40001 and claws T40001/6 and T40001/7.

To guide seal puller, thread special tool 2085/2 of the 2085 into the camshaft by hand up to the stop.

Scheme 199

Scheme 199
Scheme 199

Unscrew inner portion of 2085 two rotations (approximately 3 mm) from outer portion and secure with knurled-head screw.

Lubricate threaded head of 2085, position and forcefully screw into seal as far as possible.

Scheme 200

Scheme 200
Scheme 200

Loosen knurled bolt and turn inner part against camshaft until seal is removed.

Secure the seal remover in a vise at the flat spots. Remove seal using pliers

Installing

  1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy__valvetrain-overview) .

Do not oil sealing ring sealing lip.

Place the guide sleeve T10071/1 from T10071 on camshaft pin.

Scheme 201

Scheme 201
Scheme 201

Slide seal over guide sleeve onto shaft pin.

Remove the guide sleeve.

Press sealing ring on as far as stop with guide sleeve T10071/3 and screw T10071/4 from the T10071.

Scheme 202

Scheme 202
Scheme 202

Install camshaft sprocket.

Scheme 203

Scheme 203
Scheme 203
  1. Note installation position: Thin rib on the camshaft gear points outward -arrows- and the TDC marking on cylinder 1 is visible.

Install the bolt for camshaft sprocket using the 3036.

Note. By turning the camshaft, the valves could contact the stationary pistons at TDC. Therefore, the pistons must not be at TDC. Valves/pistons may be damaged.

Scheme 204

Scheme 204: SPECIAL TOOLS
Scheme 204: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Drip Tray VAS 6208
  2. Retainer 3036
  3. Puller T40001
  4. Ignition Coil Puller T40039
  5. Hose Clip Pliers V.A.G 1921

Scheme 205

Scheme 205
Scheme 205

Special tools and workshop equipment required

  1. Compression Tester V.A.G 1763
  2. Spark Plug Removal Tool 3122 B
  3. Ignition Coil Puller T40039
  4. Spring Type Clip Pliers VAS 5024 A

Scheme 206

Scheme 206
Scheme 206

Special tools and workshop equipment required

  1. Socket T40080
  2. Camshaft Clamp T10252
  3. Toothed Belt Tensioner T10020
  4. Locking Pin T10115

Scheme 207

Scheme 207
Scheme 207

Special tools and workshop equipment required

  1. Torque Wrench 5-60 Nm V.A.G 1783
  2. Torx® Bit Set V.A.G 1766
  3. Ratchet Insert 1/4" VAS 6234
  4. Spring Type Clip Pliers VAS 5024 A

Scheme 208

Scheme 208
Scheme 208

Special tools and workshop equipment required

  1. Engine Support Bridge 10 - 222 A
  2. Shackle (1 Set=2 Pieces) 10 - 222 A /12
  3. Locking Pin T10060A
  4. Toothed Belt Tensioner T10020
  5. Polydrive Bit And Drive Socket T10070

Scheme 209

Scheme 209
Scheme 209

Special tools and workshop equipment required

  1. Seal Puller - General Usage 2085
  2. Retainer 3036
  3. Assembly Tool T10071
  4. Puller T40001

Scheme 210

Scheme 210
Scheme 210

Special tools and workshop equipment required

  1. Valve Seal Removal Tool 3364
  2. Valve Stem Seal Driver 3365
  3. Valve Cotters Asm/Dis-Asm Device VAS 5161
  4. Guide Plate for FSI Engine VAS 5161/19B
  5. Engine and Transmission Holder VAS 6095
  6. Cylinder Head Tensioning Device VAS 6419

Scheme 211

Scheme 211
Scheme 211

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 5-50 Nm V.A.G 1331
  6. Valve Cotters Asm/Dis-Asm Device VAS 5161
  7. Guide Plate for FSI Engine VAS 5161/19B

Special tools and workshop equipment required

Scheme 212

Scheme 212
Scheme 212

Scheme 213

Scheme 213
Scheme 213

Scheme 214

Scheme 214
Scheme 214
  1. Dial Gauge Holder VW 387
  2. Dial Gauge 0-10 mm VAS 6079
  3. Engine bung set VAS 6122
  4. Not illustrated
  5. Thrust Piece 3334
  6. 2 Knurled Thumb Screws VAS 5161/12

See also:
• COOLANT PUMP
• FRONT SEALING FLANGE
• Removal and Installation
• REMOVAL AND INSTALLATION
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• RIBBED BELT
• REMOVAL AND INSTALLATION
• VIBRATION DAMPER
• SUBFRAME MOUNT, ADJUSTING
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS
• FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER
• Removal and Installation
• EXHAUST SYSTEM OVERVIEW
• TURBOCHARGER OVERVIEW
• Removal and Installation
• Removal and Installation
• TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD
• TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD
• TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW
• CAMSHAFT ADJUSTMENT VALVE 1
• EXHAUST CAMSHAFT SEAL
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS, CYLINDER HEAD INSTALLED
• VALVE STEM SEALS WITH CYLINDER HEAD REMOVED
• CAMSHAFT ADJUSTER
• TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW
• CYLINDER HEAD OVERVIEW
• CYLINDER HEAD COVER
• CYLINDER HEAD
• VALVETRAIN OVERVIEW
• CAMSHAFTS

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