3.2l - Cylinder Head, Valvetrain - Engine Code(s): Bub & Cbra Audi A3 8P рестайлинг

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. 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.

Scheme 1

1. Cylinder Head Gasket Metal gasket Replace After replacing, change coolant and engine oil
2. Cylinder Head Removal, refer to «CYLINDER HEAD, REMOVING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__cylinder-head-removing) Check for distortion (Scheme 5) Installation, refer to «CYLINDER HEAD, INSTALLING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__cylinder-head-installing) After replacing, change coolant and engine oil
3. Lifting Eye
4. 23 Nm
5. Cylinder Head Cover Gaskets Replace if damaged
6. Cylinder Head Cover Removal and installation, refer to «CYLINDER HEAD COVER»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__cylinder-head-cover)
7. Spacing Sleeve With seal Replace seal if damaged
8. 10 Nm
9. Cap
10. Seal for Filler Cap Replace if damaged
11. Rubber Buffer Replace if damaged
12. Ignition Coil Use puller for ignition coil T10095 A for removal
13. 10 Nm Bolt with spacing sleeve and seal Replace seal if damaged
14. 10 Nm
15. 10 Nm
16. Wire Harness Retainer
17. Cylinder Head Bolt Replace Observe sequence for loosening (Scheme 3)Observe sequence for tightening (Scheme 4)
18. Lifting Eye
19. 23 Nm
20. Bolt
21. Combination Valve for Secondary Air System Version and installation location «SECONDARY AIR INJECTION COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-component-overview)

Scheme 2

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

Scheme 3

Loosen the bolts in sequence -1 to 20-.

Scheme 4

Tighten bolts in 4 stages in -1 to 20- sequence as follows

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten bolts by hand.

Tighten the bolts to 30 Nm.

Tighten the bolts to 50 Nm.

Tighten an additional 180° ( 1 / 2 turn).

Scheme 5

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

1. Max. permissible distortion: 0.05 mm.

TIMING CHAIN COVERS ASSEMBLY OVERVIEW

Note. Items -1 through 3-, refer to DUAL-MASS FLYWHEEL COMPONENT OVERVIEW .

Scheme 6

1. 4 - Bolt Tightening specifications (Scheme 7)
2. 5 - Thermostat Housing Removal and installation, refer to «COOLANT THERMOSTAT HOUSING»(/audi/a3/8p-2004-2008/remont/cooling-fan/#32l-cooling-system-engine-codes-bub-cbra__coolant-thermostat-housing)
3. 6 - Bolt 10 Nm
4. 7 - Bracket Illustration does not correspond to version in vehicle
5. 8 - Gasket Replace
6. 9 - Seal 2 pieces For camshaft adjustment valve 1 -N205- and camshaft adjustment valve 1 (exhaust) -N318- Replace if leaking or damaged Replacing, refer to «UPPER TIMING CHAIN COVER SEAL, REPLACING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__upper-timing-chain-cover-seal-replacing).
7. 10 - Bolt 10 Nm
8. 11 - Camshaft Position Sensor 2 pieces Mark the electrical connector before disconnecting
9. 12 - O-ring 2 pieces Replace
10. 13 - Upper Timing Chain Cover Coat sealing surfaces with sealant when installing «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
11. 14 - Alignment Bushing 2 pieces
12. 15 - Gasket Replace
13. 16 - O-ring Replace
14. 17 - Seal Replace if leaking or damaged
15. 18 - Camshaft Timing Chain Tensioner Tightening specifications, refer to «TIMING CHAIN COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra)
16. 19 - Bolt Tightening specifications and tightening sequence (Scheme 7)
17. 20 - Cylinder Head Gasket Clean holes and fill with sealant «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
18. 21 - Fitting Pin
19. 22 - Lower Timing Chain Cover When installing, coat the sealing surfaces with sealant; sealant
20. 23 - Bolt 10 Nm Fasten in diagonal sequence in steps

Scheme 7

1. Pre-tighten the bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tight the bolts -1- and -2- to 10 Nm.

Scheme 8

1. Control Housing Removal and installation, refer to «CAMSHAFTS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts) Disassembling and assembling (Scheme 16)Check screen for dirt (Scheme 17)Lightly lubricate contact surfaces of oil seals before installing
2. 8 Nm Replace
3. Camshaft Timing Chain Before removing, mark direction of rotation with paint (Scheme 9)Remove from camshafts, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain) Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-mechanism-drive-chain-and-camshaft)
4. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
5. Intermediate Shaft
6. Thrust Washer
7. 8 Nm
8. Timing Chain Tensioning Rail Remove to remove and install upper and lower timing chain covers
9. Mounting Pin
10. Camshaft Timing Chain Tensioner - 40 Nm Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
11. Seal Replace if leaking or damaged
12. Timing Mechanism Drive Chain Sprocket Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-mechanism-drive-chain-and-camshaft)
13. Camshaft Timing Chain Sprocket Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-mechanism-drive-chain-and-camshaft)
14. 60 Nm plus an additional 90° turn Replace Counterhold vibration damper with counterhold T10069 to loosen and tighten
15. Chain Tensioner with Tensioning Rail For drive timing chain Before installation release the locking device in the chain tensioner with a small screwdriver and press the tensioning plate against the chain tensioner
16. Drive Sprocket Integral part of crankshaft
17. Power Take-Off Drive Chain Indicate direction of rotation before removing (Scheme 9)Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-mechanism-drive-chain-and-camshaft)
18. Timing Mechanism Drive Chain Guide Rail Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-mechanism-drive-chain-and-camshaft)
19. Bolts -10 Nm For guide rail
20. 18 Nm
21. 23 Nm
22. Camshaft Adjuster, Intake Side Identification: "24E" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
23. Bolt Replace Contact surface of sensor wheel at screw head must be dry when installing To loosen and tightening, counterhold with open-end spanner on camshaft hex head «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain) 60 Nm plus an additional 90° ( 1 / 4 ) turn.
24. Camshaft Timing Chain Guide Rail Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
25. Camshaft Adjustment Valve 1 -N205- For intake camshaft Mark the electrical connector before disconnecting
26. Camshaft Adjustment Valve 1 (exhaust) -N318- For exhaust camshaft Mark the electrical connector before disconnecting
27. Camshaft Timing Chain Guide Rail Clipped in at control housing

Scheme 9

Identify timing chain direction of rotation with -arrow- mark before removing, using paint -arrows-.

Scheme 10

A- Flywheel-side view

B- Vibration damper-side view

Notches -arrows- are reference points for markings on camshaft adjusters.

VALVETRAIN COMPONENT OVERVIEW

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. 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.

Scheme 11

1. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
2. Bolt Replace Counter-hold camshaft using fork wrench SW 32 for removal and installation «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain) Tightening specifications item -23- «TIMING CHAIN COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra)
3. Camshaft Adjuster, Intake Side Identification: "24E" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshaft-timing-chain)
4. Control Housing Removal and installation, refer to «CAMSHAFTS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts) Check control housing strainer for soiling before installation (Scheme 17) Lightly lubricate contact surfaces of oil seals before installing disassembling and assembling (Scheme 16)
5. Valve Stem Seal Replacing with the cylinder head installed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-stem-seals-with-cylinder-head) Replacing with the cylinder head removed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-stem-seals-with-cylinder-head)
6. Valve Spring Installation position: Larger dia. down
7. Valve Spring Plate
8. Valve Keys
9. Piston Rings 3 per camshaft Replace if leaking When replacing piston rings, do not spread too widely Install with gaps offset 120° When installing control housing item -4- lightly lubricate contact surfaces of piston rings
10. Nut Tightening specifications and tightening sequence (Scheme 15)
11. Bearing Cap Installed location (Scheme 14)Installation order «CAMSHAFTS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts)
12. Intake Camshaft Check radial clearance with Plastigage Radial clearance wear limit: 0.1 mm Run-out: max. 0.01 mm Checking axial play, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts-checking-axial-clearance) Removal and installation, refer to «CAMSHAFTS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts) Identification (Scheme 12)
13. Exhaust Camshaft Check radial clearance with Plastigage Radial clearance wear limit: 0.1 mm Run-out: max. 0.01 mm Checking axial play, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts-checking-axial-clearance) Removal and installation, refer to «CAMSHAFTS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts) Identification (Scheme 12)
14. Roller Rocker Lever Do not interchange Check roller bearing Before installing, check axial play in camshafts, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts-checking-axial-clearance) Lubricate contact surface Using the locking clamp, clip -item 15- onto the hydraulic adjusting element
15. Securing Clip Check for secure seat
16. Hydraulic Adjusting Element Do not interchange Before installing, check axial play in camshafts, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__camshafts-checking-axial-clearance) Lubricate contact surface
17. Cylinder Head Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-guides-checking) Reface valve seat, refer to «REFACING VALVE SEATS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__refacing-valve-seats)
18. Intake Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-guides-checking) Refacing valve seats, refer to «REFACING VALVE SEATS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__refacing-valve-seats)
19. Exhaust Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valve-guides-checking) Reface valve seats, refer to «REFACING VALVE SEATS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__refacing-valve-seats)
20. Bolt 8 Nm

Scheme 12

Camshaft identification is located between cylinder 4 and cylinder 5 cam pair.

A - Exhaust camshaft; Identification 022 - Index 101

B - Intake camshaft; Identification 022 - Index 102

Scheme 13

Lightly coat bearing cap 7 and 8 contact surface -hatched area- with adhesive lubricating paste.

Scheme 14

1. Tops of intake and exhaust camshaft bearing caps -arrow A- face toward outside.

Scheme 15

Tighten nuts on intake camshaft -A- in 5 stages as follows

1. Install bearing cap 5 and 9 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 5 and 9 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 1 and 13 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 7 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 3 and 11 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Tighten nuts on exhaust camshaft -B- in 5 stages as follows

1. Install bearing cap 6 and 10 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 6 and 10 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 2 and 14 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 8 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 4 and 12 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Scheme 16

1. Guide track, clipped in at control housing
2. Control housing
3. Camshaft Adjustment Valve 1 -N205
4. Camshaft Adjustment Valve 1 (exhaust) -N318
5. Bolt

Scheme 17

Unclip screen -2- at backside of control housing -1- and remove any contaminants.

VALVE DIMENSIONS

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

FASTENER TIGHTENING SPECIFICATIONS

Cylinder Head Cover - Tightening Specifications and Tightening Sequence

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

Cylinder Head - Tightening Specifications and Tightening Sequence

Tighten bolts in 4 stages in -1 to 20- sequence as follows

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten bolts by hand.

Tighten the bolts to 30 Nm.

Tighten the bolts to 50 Nm.

Tighten an additional 180° ( 1 / 2 turn).

Upper Timing Chain Cover - Tightening Specifications and Tightening Sequence

1. Pre-tighten the bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tight the bolts -1- and -2- to 10 Nm.

Camshafts - Tightening Specifications and Tightening Sequence

Tighten nuts on intake camshaft -A- in 5 stages as follows

1. Install bearing cap 5 and 9 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 5 and 9 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 1 and 13 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 7 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 3 and 11 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Tighten nuts on exhaust camshaft -B- in 5 stages as follows

1. Install bearing cap 6 and 10 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 6 and 10 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 2 and 14 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 8 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 4 and 12 to 5 Nm plus an additional 45° ( 1 / 8 turn).

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763
3. Puller For Ignition Coil T10095 A
4. Assembly Tool T10118

Procedure

1. Engine oil temperature min. 30 °C / 86 °F.
2. Battery voltage at least 12.5 V.

Switch off ignition.

Open engine compartment E-box cover and remove fuel injector fuse -29-.

Scheme 18

Disconnect electrical harness connectors to ignition coils, to do so attach T10118 on release button -arrow- and carefully disconnect harness connector.

Scheme 19

Attach T10095 A on ignition coils -arrow- as depicted in the illustration and pull out ignition coils in succession.

Scheme 20

Using 3122 B, remove spark plugs.

Check compression using V.A.G 1763.

Have a second technician press accelerator pedal completely and at the same time operate starter long enough until pressure increase no longer appears on tester.

Assembly is in reverse order of removal, note the following

CAMSHAFTS, CHECKING AXIAL CLEARANCE

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial gauge

Test Sequence

Perform the measurement with the roller rocker levers and hydraulic adjusting elements removed. The bearing cap of axial bearing for respective camshaft remains installed.

Secure VW 387 to dial gauge on cylinder head.

Scheme 21

Determine axial clearance.

1. Axial play wear limit: 0.10 mm.

CAMSHAFT, MEASURING RADIAL PLAY

Procedure

Camshafts, removal. Refer to CAMSHAFTS .

Clean bearing cap and bearing journals.

Removing cam follower. Refer to CAMSHAFTS .

Place Plastigage over entire width of bearing journal or into bearing.

1. Plastigage must rest in center of bearing.

Position the bearing cap and tighten it to 5 Nm. (Scheme 15)without rotating the camshaft.

Reinstall bearing cap.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. Wear limit: 0.1 mm.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial gauge

Test Sequence

Insert valve into valve 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 22

1. Valve stem tip must seal with valve guide.

Determine tilt clearance.

1. Tilt clearance wear limit: 0.8 mm.

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. The valve guides cannot be replaced. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

REFACING VALVE SEATS

Note. If a perfect contact pattern is not achieved by grinding the valve seats, reface the valve seats.

Special tools and workshop equipment required

1. Depth gauge
2. Valve seat refacing tool

Note. When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves. It is particularly important to check valve guides for wear on engines with higher mileage performance. Refer to VALVE GUIDES, CHECKING . Only reface valve seats enough until a perfect contact pattern is obtained. Before refacing, determine maximum refacing dimension. If the reworking dimension is exceeded, the function of the hydraulic lifters can no longer be guaranteed and therefore the cylinder head must be replaced.

Determining maximum allowable reworking dimension

Insert valve and press it firmly against the valve seat.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Measure distance -a- between end of valve stem and the upper cylinder head surface with a depth gauge.

Scheme 23

Calculate the maximum allowable refacing dimension from the measured distance and minimum dimension.

Measured distance minus minimum dimension = max. permissible reworking dimension.

Note. If the maximum allowed refacing dimension is 0 mm or less than 0 mm, repeat measurement using new valve. If measurement result is still 0 mm or less than 0 mm, replace cylinder head.

Refacing intake valve seat

Scheme 24

a - Dia. 30.6 mm

b - Maximum permissible refacing dimension

c - 0.9 to 1.5 mm

d - Max. dia. 35.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45° valve seat angle

β - 30° upper correction angle

gamma - 60° lower correction angle

Note. Calculating maximum allowable refacing dimension REFACING VALVE SEATS .

Refacing exhaust valve seat

a - Dia. 26.7 mm

b - Maximum permissible refacing dimension

c - 1.2 to 1.7 mm

d - Max. dia. 29.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45° valve seat angle

β - 30° upper correction angle

gamma - 60° lower correction angle

Note. Calculating maximum allowable refacing dimension REFACING VALVE SEATS .

CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Locking Pin T10060 A
2. Ignition Coil Puller T10095 A
3. Assembly Tool T10118

Removing

Remove tool formed insert under luggage compartment floor covering.

Remove cover -arrow- for battery compartment

Scheme 25

Remove formed insert from over the battery.

With ignition switched off, disconnect Battery Ground (GND) cable -arrow-.

Scheme 26

Remove center noise insulation fasteners -1 to 3-.

Scheme 27

Remove right noise insulation fasteners -1 to 3-.

Scheme 28

If equipped, remove vacuum hose -2- to air guide hose.

Scheme 29

Disconnect air guide hose -1- at throttle valve control module -J338-.

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Pull off air guide cover -1-, disengage clips sideways to do so.

Scheme 30

Unclip air duct -2-.

Remove lower section of air duct -arrows-.

Scheme 31

Remove lower section of air filter housing -arrows-.

Scheme 32

Disconnect secondary air hose at position indicated by -arrow-.

Scheme 33

Free up air hose to Secondary Air Injection (AIR) pump.

Disconnect the connectors -2- and -3-.

Scheme 34

Disconnect crankcase ventilation hose -1-.

Remove throttle valve control module -J338- from intake manifold -arrows-.

Scheme 35

Disconnect electrical harness connectors to ignition coils, to do so attach T10118 on release button -arrow- and carefully disconnect harness connector.

Attach T10095 A on ignition coils -arrow- as depicted in the illustration and pull out ignition coils in succession.

Remove electrical wiring guide from intake manifold and lay aside.

Note. Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap -1- and slide release button -2- to the rear.

Remove rear vacuum hoses -2 to 5- at intake manifold.

Scheme 36

Note. Ignore -1-.

Remove wiring connection from intake manifold -arrows- and lay back with hoses connected.

Remove intake manifold bolts -arrows-.

Scheme 37

Remove top mounting bolts for fan shroud -top arrows-.

Scheme 38

Remove oil dipstick.

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Scheme 39

Remove ribbed belt.

Free up coolant hose at bottom on fan shroud.

Scheme 40

Disconnect electrical harness connector -3- at secondary air injection (AIR) pump motor -V101-.

Free up cable.

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Disconnect electrical harness connectors -1- for coolant fans at bottom on fan shroud.

Remove mounting bolts for fan shroud at bottom -bottom arrows-.

Pull out fan shroud downward with both fans.

Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.

Scheme 41

Remove bolts -arrow- for A/C compressor.

Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.

Remove electrical wire -1- on generator.

Scheme 42

Separate the electrical connector -2-.

Note. Ignore -3-.

Remove upper idler roller -1-.

Scheme 43

Remove mounting bolts -2- and -3- for generator.

Note. Generator can be removed from bracket only with the upper mounting bolt still installed.

Remove generator with electrical wiring connected from accessory assembly bracket.

Remove generator downward and to the left.

Disconnect electrical harness connector -arrow- at after-run coolant pump -V51-.

Scheme 44

Remove bolts -1 to 5- and remove accessory assembly bracket.

Pull after-run coolant pump -V51-, with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.

Note. Coolant pump remains on the engine with coolant hoses connected.

Disengage for engine speed (RPM) sensor -G28- connector -arrow- from bracket on oil dipstick guide tube.

Scheme 45

Remove bolt -3- and remove oil dipstick guide tube -2-.

Scheme 46

Remove bolt -4- and remove vacuum reservoir -1- from intake manifold.

Lay vacuum reservoir aside with lines connected.

Remove bolts -arrows- at front of intake manifold.

Scheme 47

Remove vacuum line -arrow- at variable intake manifold actuator.

Scheme 48

Note. Ignore -1- and -2-.

Protect intake manifold from damage with a clean cloth -1-.

Scheme 49

Swing intake manifold forward -arrow 1- and then pull slightly to left -arrow 2-.

Note. Seal intake channel in cylinder head with clean cloth or foam pieces so that no small parts can fall in.

Remove right fuel line bracket on cylinder head cover.

Remove left electrical line bracket from timing chain cover.

Loosen cylinder head cover bolts in sequence -11 to 1-.

Installing

1. Tightening specifications, refer to «CYLINDER HEAD COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra) .

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover seals and screws if damaged.

Tighten cylinder head cover bolts in sequence -1 to 11-.

Install intake manifold. Refer to Removal and Installation .

CYLINDER HEAD, REMOVING

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Shop Crane VAS 6100

Procedure

1. Engine installed.

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Heat shield boots that were removed should be installed in the same location during installation.

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

Remove the intake manifold. Refer to Removal and Installation .

Remove coolant hoses to heater core on bulkhead -arrows-.

Scheme 50

Disconnect following hose connections

Scheme 51

1. Coolant hose to reservoir
2. Vacuum hose to Evaporative Emission (EVAP) Canister
3. Vacuum hose to Leak Detection Pump
4. Fuel supply line
5. Coolant hose to reservoir

Disconnect coolant hoses at positions indicated by -arrows-.

Scheme 52

Note. Ignore -1-. Shown in illustration on vehicle with Direct Shift Gearbox transmission.

Remove wiring connections with coolant and vacuum hoses.

Remove camshaft timing chain from camshafts. Refer to CAMSHAFT TIMING CHAIN .

Note. Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.

Remove front exhaust pipe from exhaust manifolds -arrows-.

Scheme 53

Loosen and remove cylinder head bolts in sequence shown.

Engage 3033 as follows

Scheme 54

1. Belt pulley side: Position -3-.
2. Timing chain side: Position -10-.

Note. 3033 positions marked with 1 to 12 face toward timing chain side.

Carefully raise cylinder head.

Place clean cloth in cylinder so that no dirt can enter between cylinder wall and pistons.

CYLINDER HEAD, INSTALLING

Special tools and workshop equipment required

1. Camshaft Bar T10068 A

Procedure

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. Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage. The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head. When installing exchanged cylinder head, contact surfaces between hydraulic adjusting elements, roller rocker levers and cam running surfaces must be oiled before installation. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Secure all hose connections with hose clamps appropriate for the model. When replacing cylinder head or cylinder head seal, coolant and engine oil must be changed.

Position camshafts at TDC marking before positioning cylinder head.

Cams -A- of cylinder 1 must face each other.

Scheme 55

Verify camshaft TDC position

Scheme 56

1. It must be possible to insert T10068 A into both shaft grooves.

Check again if crankshaft is positioned at TDC -arrow-.

Scheme 57

Position cylinder head gasket.

1. Observe the centering pins in cylinder block.
2. Observe cylinder head seal location, identification: Part number must be visible from intake side.

Install cylinder head.

Insert cylinder head bolts and tighten by hand.

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten cylinder head bolts. (Scheme 4)

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

Install camshaft timing chain CAMSHAFT TIMING CHAIN .

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Install intake manifold. Refer to Removal and Installation .

Connect Ground (GND) cable to battery. Refer to Removal and Installation .

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

Tightening Specifications

UPPER TIMING CHAIN COVER SEAL, REPLACING

Special tools and workshop equipment required

1. Wheel Bearing Assembly Set 3253
2. Fitting Sleeve 3378

Procedure

1. Upper timing chain cover removed.

Drive out seal with a drift.

Fit seal into upper camshaft timing chain cover -1- using 3378 and drive in flush using 3253/6.

Scheme 58

CAMSHAFT TIMING CHAIN

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Black Sealant
3. Sealing Compound

Removing the camshaft timing chain

1. Engine installed.

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

Remove the intake manifold. Refer to Removal and Installation .

Disconnect electrical connector to engine coolant temperature (ECT) sensor -G62-.

Scheme 59

Disconnect coolant hoses at positions indicated by -arrows-.

Scheme 60

Remove the bolts -arrows-.

Scheme 61

Pull transmission oil cooler coolant pipe bracket toward left.

Swing Secondary Air Injection (AIR) system hose bracket forward.

Remove bolt -arrow- at wiring harness bracket.

Scheme 62

Remove coolant thermostat housing -2- while pressing coolant pipe -1- toward coolant pump with pry bar.

Scheme 63

Vehicles with engine code BUB

Disconnect the hose -3- and the vacuum hose -2- from the Secondary Air Injection (AIR) combination valve.

Scheme 64

Disconnect coolant hose -1-.

Vehicles with engine code CBRA

Disconnect the hose -1- and the vacuum hose -2- from the left Secondary Air Injection (AIR) combination valve.

Scheme 65

Note. Ignore -3- and -arrows-.

All Vehicles

Identify and disconnect electrical connectors

Scheme 66

1. Camshaft position sensor -G40
2. Camshaft position (CMP) sensor 2 -G163
3. Camshaft adjustment valve 1 -N205
4. Camshaft adjustment valve 1 (exhaust) -N318

Remove wiring guide from camshaft timing chain cover.

Loosen cylinder head cover bolts in sequence -11 to 1-.

Set crankshaft to TDC mark by turning crankshaft on vibration damper screw in direction of engine rotation -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, T10068 A must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.

Remove camshaft timing chain tensioner -arrow-.

Scheme 67

Remove bolts -1 to 3- and upper timing chain cover horizontally from cylinder head. When doing so, ensure cylinder head bolt is not damaged.

Remove bolts -arrows- and remove guide track -1-.

Scheme 68

Remove T10068 A.

Note. Camshaft bar T10068 A must not be inserted when loosening or tightening camshaft adjuster screws.

Remove retaining screw at intake side camshaft adjuster while counterholding camshaft hex head with open end wrench SW 32.

Scheme 69

Remove intake side camshaft adjuster.

Remove retaining bolt at exhaust side camshaft adjuster while counterholding camshaft hex head with open end wrench SW 32.

Scheme 70

Remove camshaft adjuster exhaust side.

Lay camshaft timing chain over camshaft adjuster valves.

Installing the camshaft timing chain (adjusting the timing)

1. Tightening specifications, refer to «TIMING CHAIN COVERS ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-chain-covers-assembly-overview), (Scheme 7) and «TIMING CHAIN COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra).

Insert guide track -1- and tighten bolts -arrows-.

Check TDC marking on crankshaft again -arrow-.

Verify camshaft TDC position

1. Cams -A- of cylinder 1 must face each other.

1. It must be possible to insert T10068 A into both shaft grooves.

If necessary, turn camshafts at hex head surfaces -arrows- to correct position using open end wrench SW 32.

Scheme 71

Note. Both camshaft adjusters (identification: 24E on intake side and 32A on exhaust side) can only be bolted in one position on the camshaft mountings -arrows- by an alignment pin.

First install intake side camshaft adjuster

Scheme 72

Turn sensor wheel -1- in camshaft adjuster clockwise -arrow- to stop.

Note. Camshaft bar T10068 A must not be used as counterhold.

Hand tighten intake side camshaft adjuster in this position to intake camshaft.

Scheme 73

1. Contact surface of sensor wheel at screw head must be dry when installing.
2. The "24E" marking -1- and the tooth behind it must align with notch -2- in control housing. Markings on control housing (Scheme 10).

Lay camshaft timing chain in this position tightly against intake side camshaft adjuster sprocket.

Starting with the toothed that has the "24E" marking, count exactly 16 rollers to the right on the timing chain. Mark this roller with a color marker.

Scheme 74

Note. Exhaust camshaft adjuster is locked in the rest state. Therefore sensor wheel cannot be rotated when adjusting the valve timing. If locking mechanism is in rest state is not engaged (locked) turn adjuster in both directions by hand until it locks. If that is not possible, replaced camshaft adjuster.

Now insert exhaust camshaft adjuster "32A" with tooth at arrow marking -1- into camshaft roller chain so that the exact, previously counted 16 rollers lie between marking "24E" and "32A" and markings -1- and -2- align.

Scheme 75

Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.

Check the position of both camshaft adjusters one more time for correct adjustment.

Remove T10068 A.

Tighten bolt on camshaft adjuster intake side by counter-holding with open-end spanner on camshaft hex head.

Tighten bolt on camshaft adjuster exhaust side by counter-holding with open-end spanner on camshaft hex head.

Scheme 76

Set crankshaft to TDC mark by turning crankshaft on vibration damper bolt 2 turns in direction of engine rotation -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, the T10068 A must engage in both shaft grooves.

If the camshaft bar cannot be inserted

Repeat valve timing adjustment.

Clean old sealant from 3 mm holes -arrows- in cylinder head seal.

Scheme 77

Fill 3 mm holes in cylinder head seal using black sealant.

Note. With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Replace seal in upper timing chain cover. Refer to UPPER TIMING CHAIN COVER SEAL, REPLACING .

Clean sealing surfaces so they are completely free of any oil or grease.

Check whether fitting sleeves -2- and -3- are inserted in upper timing chain cover.

Scheme 78

Insert a new gasket -1- and a new seal -4-.

Lightly coat clean upper timing chain cover sealing surfaces -shown hatched- with sealing paste.

Note. Also coat sealing surfaces below cylinder head seal with some sealant do not kink cylinder head seal when doing so. Upper timing chain cover must be installed within 5 minutes of applying sealing paste.

Set upper timing chain cover in place and tighten bolts as follows

1. Tighten bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tight the bolts -1- and -2- to 10 Nm.

Tighten camshaft timing chain tensioner -arrow-.

Turn crankshaft 2 times in direction of engine rotation and check valve timing again.

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Install intake manifold. Refer to Removal and Installation .

Install coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

1. Replace bolt.

1. 90° corresponds to a 1/4 turn

TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Counter-Holder Tool T10069
3. Black sealant
4. Sealing compound

Removing

1. Engine removed. Refer to «ENGINE, REMOVING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-engine-assembly-engine-codes-bub-cbra__engine-removing) .
2. Engine and transmission separated. Refer to «ENGINE AND DSG TRANSMISSION, SEPARATING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-engine-assembly-engine-codes-bub-cbra__engine-and-dsg-transmission-separating) .
3. Dual-mass flywheel removed. Refer to «DUAL MASS FLYWHEEL»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__dual-mass-flywheel) .
4. Intake manifold removed. Refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra) .
5. Cylinder head cover removed. Refer to «CYLINDER HEAD COVER»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__cylinder-head-cover) .
6. Coolant thermostat housing removed. Refer to «COOLANT THERMOSTAT HOUSING»(/audi/a3/8p-2004-2008/remont/cooling-fan/#32l-cooling-system-engine-codes-bub-cbra__coolant-thermostat-housing) .
7. Oil pan removed. Refer to «OIL PAN»(/audi/a3/8p-2004-2008/remont/lubrication-system/#32l-lubrication-engine-codes-bub-cbra__oil-pan) .

Set crankshaft to TDC mark by turning crankshaft on vibration damper bolt in direction of engine rotation -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, T10068 A must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.

Identify and disconnect electrical connectors

1. Camshaft position sensor -G40
2. Camshaft position (CMP) sensor 2 -G163
3. Camshaft adjustment valve 1 -N205
4. Camshaft adjustment valve 1 (exhaust) -N318

Remove camshaft timing chain tensioner -arrow-.

Remove bolts -1 to 3- and upper timing chain cover horizontally from cylinder head. When doing so, ensure cylinder head screw is not damaged.

Remove bolts and remove lower timing chain cover -arrow- horizontally from cylinder block. When doing so, ensure cylinder head bolt is not damaged.

Scheme 79

Press crankshaft seal timing chain side out of cover.

Identify timing chain direction of rotation with arrow mark before removing, using paint -arrows-.

Remove bolts -arrows- and remove guide track -1-.

Remove camshaft timing chain from intermediate shaft sprocket.

Carefully remove camshaft timing chain behind cylinder head seal rib.

Loosen chain sprocket bolt -arrow- on intermediate shaft approximately 1 turn.

Scheme 80

Counter hold at vibration damper with T10069 when doing so.

Scheme 81

Remove timing mechanism drive chain tensioner -arrows-.

Scheme 82

Remove bolt -arrow- and remove drive chain together with chain sprockets from intermediate shaft.

Installing

1. Tightening specifications, refer to «TIMING CHAIN COVERS ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__timing-chain-covers-assembly-overview) , «TIMING CHAIN COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra) .

When reinstalling a used timing mechanism drive chain, note running direction marking -lower arrow-.

Install drive chain together with large chain sprocket on intermediate shaft.

Scheme 83

1. Installation only possible in one position.

If large chain sprocket cannot be installed, rotate intermediate shaft slightly.

Check if crankshaft is in "TDC" position

1. Milled drive chain sprocket tooth must align with bearing joint -arrow A-.
2. Tab on intermediate shaft sprocket must align with notch -arrow B- on intermediate shaft thrust washer.

Install small chain sprocket on intermediate shaft.

1. Installation only possible in one position.

Replace the chain sprocket bolt for the intermediate shaft.

Tighten chain sprocket bolt -arrow- by hand.

Release locking splines in chain tensioner with small screwdriver -arrow-.

Scheme 84

Press tensioning rail against chain tensioner and tighten chain tensioner in this position -arrows-.

Tighten chain sprocket bolt -arrow-.

Counter hold with T10069 at vibration damper bolt.

Place the timing chain on the camshaft adjuster in such a way that the 2 individual copper color chain sprockets -CA- align with the markings on the camshaft adjuster. It is possible that the intake camshaft adjust will have to be rotated slightly.

Scheme 85

Mount the timing chain on the small chain sprocket. The marking -B- must align with the center copper color chain link -A-.

Insert guide track -1- and tighten bolts -arrows-.

Remove T10068 A.

Set crankshaft to TDC mark by turning crankshaft on vibration damper bolt 2 turns in direction of engine rotation -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, the T10068 A must engage in both shaft grooves.

Note. Marked links now take on an undefined position.

If the camshaft bar cannot be inserted

Repeat valve timing adjustment.

Clean old sealant from 3 mm holes -arrows- in cylinder head seal.

Note. With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Clean sealing surfaces at engine and both covers; they must be free of oil and grease.

Check whether lower timing chain cover alignment pins are inserted in cylinder block.

Scheme 86

Lightly coat clean lower timing chain cover sealing surfaces -shown hatched- with sealing paste.

Note. Lower timing chain cover must be installed within 5 minutes of applying sealing paste.

Tighten lower timing chain cover bolts -arrow- diagonally in stages.

Fill 3 mm holes in cylinder head seal -arrows- using black sealant.

Replace seal in upper timing chain cover. Refer to UPPER TIMING CHAIN COVER SEAL, REPLACING .

Check whether alignment sleeves -2- and -3- are inserted in upper timing chain cover.

Insert a new gasket -1- and a new seal -4-.

Lightly coat clean upper timing chain cover sealing surfaces -shown hatched- with sealing paste.

Set upper timing chain cover in place and tighten bolts as follows

1. Tight the bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tight the bolts -1- and -2- to 10 Nm.

Tighten camshaft timing chain tensioner -arrow-.

Turn crankshaft 2 times in direction of engine rotation and check valve timing again.

Install crankshaft seal, timing chain side. Refer to CRANKSHAFT SEAL, REPLACING .

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Install intake manifold. Refer to Removal and Installation .

Install coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Install oil pan OIL PAN .

Install dual-mass flywheel. Refer to DUAL MASS FLYWHEEL .

Install engine. Refer to ENGINE, INSTALLING .

Add engine oil and check oil level. Refer to OIL LEVEL, CHECKING .

CAMSHAFTS

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Adhesive lubricating paste.

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. Heat shield boots that were removed should be installed in the same location during installation.

Remove camshaft timing chain from camshafts. Refer to CAMSHAFT TIMING CHAIN .

Remove control housing -arrows-.

Scheme 87

Carefully pull control housing off camshaft seals.

Remove intake camshaft -A- as follows

1. Remove bearing caps 1 and 13.
2. Remove bearing caps 3 and 11.
3. Remove bearing cap 7.
4. Loosen bearing caps 5 and 9 alternately and in diagonal sequence, and remove.

Remove exhaust camshaft -B- as follows

1. Remove bearing caps 2 and 14.
2. Remove bearing caps 4 and 12.
3. Remove bearing cap 8.
4. Loosen bearing caps 6 and 10 alternately and in diagonal sequence, and remove.

Carefully remove camshafts and place on a clean surface.

Installing

1. Tightening specifications, refer to «VALVETRAIN COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-bub-cbra__valvetrain-component-overview), (Scheme 15).

Note. When installing camshafts, crankshaft must not be at TDC with any piston. Valves and/or pistons may be damaged. After installing the camshafts, the engine may not be started for approximately 30 minutes. 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.

Install the hydraulic adjusting elements into the cylinder head.

Lay roller rocker lever -1- on valve stem ends and clip in the hydraulic adjusting elements -2-.

Scheme 88

Oil journal surfaces of camshafts.

Place respective camshaft into camshaft bearings of cylinder head.

Note camshaft identification between cylinder 4 and cylinder 5 cam pair

A - Exhaust camshaft - Identification 022 - Index 101

B - Intake camshaft - Identification 022 - Index 102

Install the camshafts into the cylinder head in such a way so that the cams -A- on cylinder 1 are pointing toward each other.

Observe installed position of bearing caps

1. Points -arrow A- of intake and exhaust camshaft bearing caps face outwards.
2. Identification on bearing caps is legible when read from intake side.

Lightly coat bearing cap 7 and 8 contact surface -hatched area- with adhesive lubricating paste.

Install intake camshaft -A- as follows

1. Fasten bearing caps 5 and 9 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing caps 1 and 13.
3. Fasten bearing cap 7.
4. Fasten bearing caps 3 and 11.

Install exhaust camshaft -B- as follows

1. Fasten bearing caps 6 and 10 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing caps 2 and 14.
3. Fasten bearing cap 8.
4. Fasten bearing caps 4 and 12.

Position camshafts in cylinder head to TDC.

1. It must be possible to insert T10068 A into both shaft grooves.

If necessary, turn camshafts at hex head surfaces -arrows- to correct position using open end wrench SW 32.

Note. When turning camshafts, crankshaft must not be at TDC with any piston. Valves and/or pistons may be damaged.

Unclip screen -2- at backside of control housing -1- and remove any contaminants.

Lightly oil camshaft seal contact surfaces in control housing.

Lightly oil sealing ring contact surfaces of camshafts and carefully slide control housing over camshaft sealing rings.

Tighten control housing -arrows-.

Install camshaft timing chain (adjust valve timing) CAMSHAFT TIMING CHAIN .

1. 45° corresponds to 1 / 8 turn.

VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING

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. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate F/Vr6 And W12 Engine VAS 5161/25
5. Adapter T40012

Procedure

1. Engine removed.

Remove camshafts. Refer to CAMSHAFTS .

Using 3122 B, remove spark plugs.

Place VAS 5161/3 on valve spring plate and loosen stuck valve retainers using a plastic hammer.

Scheme 89

Place VAS 5161/25 from VAS 5161 on cylinder head.

Scheme 90

Secure guide plate with a nut -1-.

Screw T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Rear valve row procedure

Screw VAS 5161/6 with VAS 5161/5 into guide plate.

Scheme 91

Push VAS 5161/8 into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve retainers.

Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Front valve row procedure

Screw VAS 5161/6 with VAS 5161/5 onto cylinder head.

Scheme 92

Push the VAS 5161/17 onto the VAS 5161/8.

Push installation cartridge into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve retainers.

Lightly move knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Procedure for both valve rows

Pull off valve stem oil seals using 3364.

Scheme 93

Note. For pressing on green-colored valve stem seals from delivery program, the 3365 must be drilled to 10.5 mm in dia. Mark the drilled driver for later reuse. A plastic sleeve -A- is supplied with new valve shaft seals.

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

Lightly coat sealing lips of valve stem seal with oil.

Push valve stem seal onto plastic sleeve.

Carefully press valve stem oil seal onto valve guide using 3365.

Remove plastic sleeve again.

If the valve keys were removed from the installation cartridge, they must be inserted into VAS 5161/18 next.

Scheme 94

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

Install valve spring and valve spring plate.

Installed position of valve spring

Scheme 95

1. The larger dia. -arrow- faces toward cylinder head.

Rear valve row procedure

Fasten the guide plate to cylinder head again as shown in illustration.

Insert installation cartridge into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.

Release pressure fork with the knurled bolt still pulled.

Front valve row procedure

Insert installation cartridge with knurled spacer wheel into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.

Release pressure fork with the knurled bolt still pulled.

Install camshafts CAMSHAFTS .

Install sparks plugs.

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 retainer disassembly and assembly device VAS 5161 with guide plate VAS 5161/25
4. Engine and transmission holder VAS 6095
5. Cylinder head tension device VAS 6419

Procedure

Remove camshafts. Refer to CAMSHAFTS .

Mark the location 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.

Insert the VAS 6419 in the VAS 6095.

Scheme 96

Tension the cylinder head on the VAS 6419 as shown in the illustration.

Connect the VAS 6419 to 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 VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Place VAS 5161/25 from VAS 5161 on cylinder head.

Scheme 97

Secure guide plate with a nut -1-.

Rear valve row procedure

Screw VAS 5161/6 with VAS 5161/5 into guide plate.

Scheme 98

Push VAS 5161/8 into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Front valve row procedure

Screw VAS 5161/6 with VAS 5161/5 onto cylinder head.

Scheme 99

Push the VAS 5161/17 onto the VAS 5161/8.

Push installation cartridge into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Procedure for both valve rows

Pull off valve stem oil seals using 3364.

Note. For pressing on green-colored valve stem seals from delivery program, the 3365 must be drilled to a dia. of 10.5 mm. Mark the drilled driver for later reuse. A plastic sleeve -A- is supplied with new valve shaft seals.

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

Lightly coat sealing lips of valve stem seal with oil.

Push valve stem seal onto plastic sleeve.

Carefully press valve stem oil seal onto valve guide using 3365.

Remove plastic sleeve again.

If the valve keepers were removed from the installation cartridge, they must be inserted into VAS 5161/18 next.

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

Install valve spring and valve spring plate.

Installed position of valve spring

1. The larger dia. -arrow- faces toward cylinder head.

Rear valve row procedure

Fasten the guide plate to cylinder head again as shown in illustration.

Insert installation cartridge into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.

Release pressure fork with the knurled bolt still pulled.

Front valve row procedure

Insert installation cartridge with knurled spacer wheel into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.

Release pressure fork with the knurled bolt still pulled.

Install camshafts CAMSHAFTS .

Install sparks plugs.

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. 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.

Scheme 100

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. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate F/Vr6 And W12 Engine VAS 5161/25
5. Adapter T40012

Scheme 101

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763
3. Puller For Ignition Coil T10095 A
4. Assembly Tool T10118

Scheme 102

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 with guide plate VAS 5161/25
4. Engine and transmission holder VAS 6095
5. Cylinder head tension device VAS 6419

Special tools and workshop equipment required

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

1. Dial Gauge Holder VW 387
2. Locking Pin T10060 A
3. Lifting Tackle 3033
4. Shop Crane VAS 6100
5. Camshaft Bar T10068 A
6. Wheel Bearing Assembly Set 3253
7. Fitting Sleeve 3378
8. Counter-Holder Tool T10069

See also:
• SECONDARY AIR INJECTION COMPONENT OVERVIEW
• DUAL-MASS FLYWHEEL COMPONENT OVERVIEW
• COOLANT THERMOSTAT HOUSING
• Removal and Installation
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• ENGINE, REMOVING
• ENGINE AND DSG TRANSMISSION, SEPARATING
• DUAL MASS FLYWHEEL
• OIL PAN
• CRANKSHAFT SEAL, REPLACING
• ENGINE, INSTALLING
• OIL LEVEL, CHECKING
• CYLINDER HEAD, REMOVING
• CYLINDER HEAD, INSTALLING
• CYLINDER HEAD COVER
• UPPER TIMING CHAIN COVER SEAL, REPLACING
• CAMSHAFT TIMING CHAIN
• TIMING CHAIN COMPONENT OVERVIEW
• CAMSHAFTS
• TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN
• VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING
• CAMSHAFTS, CHECKING AXIAL CLEARANCE
• VALVE GUIDES, CHECKING
• REFACING VALVE SEATS
• VALVE DIMENSIONS
• TIMING CHAIN COVERS ASSEMBLY OVERVIEW
• VALVETRAIN COMPONENT OVERVIEW