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

Scheme 111

1. O-ring Replace Coat with oil before installing
2. Oil Dipstick Guide Tube
3. Bolt 9 Nm
4. Bolt 9 Nm
5. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «CAMSHAFT ADJUSTMENT VALVE»(ref-496097-S20113467142012082100000)
6. Seal Coat with oil before installing Replace if damaged
7. Bolt Tightening order «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(ref-496097-S40245964682012082100000)
8. Upper Timing Chain Cover Removing and installing, refer to «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(ref-496097-S40245964682012082100000)
9. Seal replace if damaged
10. O-ring Replace Oil before assembling
11. Alignment Pins Centering the cover
12. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(ref-496097-S14639437392012082100000)
13. Bolt Replace Tightening order «TIMING CHAIN COVER ASSEMBLY OVERVIEW»(ref-496097-S40245964682012082100000)
14. Shaft Seal For the vibration damper Replacing, refer to «VIBRATION DAMPER SHAFT SEAL»(ref-496097-S19201136422012082100000) .
15. Plug Replace

Scheme 112

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

Tighten the bolts to 9 Nm.

Scheme 113

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

1. Tighten the bolts to 9 Nm.

2. Tighten the bolts an additional 45°.

Timing Chain Guard Lower Section - Tightening Sequence for 8 Bolts

Tighten the bolts -1 through 8- in 2 stages

1. Tighten the bolts to 4 Nm.

2. Tighten the bolts an additional 45°.

Scheme 114

1. Bolt 9 Nm
2. Chain Tensioner Is under tension Disconnect the locking pin T40011 before removing
3. Timing Chain Tensioning Rail
4. Guide Bolt 20 Nm
5. Bolt 9 Nm
6. Control Valve 35 Nm Left thread On engine codes CBFA and CCTA with assembly tool T10352
7. Bolt Replace M6: 8 Nm plus and additional 90° turn M8: 20 Nm plus and additional 90° turn Replace
8. Washer
9. Bearing Bracket
10. Camshaft Timing Chain Guide Rail
11. Camshaft Housing
12. Camshaft Timing Chain Before removing, mark the direction of rotation with paint
13. Camshaft Timing Chain Guide Rail
14. Guide Bolt 20 Nm
15. Three Stage Chain Sprocket Crankshaft Installed location «CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(ref-496097-S33722363212012082100000)

Scheme 115

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

Scheme 116

1. Bolt Replace 9 Nm
2. Balance Shaft Exhaust side Replace after removing Lubricate the bearing with engine oil Replacing, refer to «EXHAUST CAMSHAFT BALANCE SHAFT»(ref-496097-S41433336762012082100000) .
3. Pipe for the Balance Shaft Installed location «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(ref-496097-S40662215982012082100000)
4. Chain Tensioner 65 Nm
5. Cylinder Block
6. Balance Shaft Intake side Replace after removing Lubricate the bearing with engine oil Replacing, refer to «INTAKE CAMSHAFT BALANCE SHAFT»(ref-496097-S25948323392012082100000) .
7. O-ring Lubricate with engine oil
8. Mounting Pin Lubricate with engine oil Installed location «BALANCE SHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(ref-496097-S40662215982012082100000)
9. Intermediate Shaft Sprocket For the balance shaft The intermediate shaft sprocket must be replaced if the bolt -12- is loosened.
10. Bolt Replace 9 Nm
11. Washer
12. Bolt The intermediate shaft sprocket must be replaced if the bolt -9- is loosened. Tightening order «INTERMEDIATE SHAFT SPROCKET TIGHTENING SEQUENCE»(ref-496097-S06120032442012082100000)
13. Guide Rail For timing chain
14. Guide Pins 20 Nm
15. Tensioning Rail For timing chain
16. Guide Pins 20 Nm
17. Timing Chain Removing, refer to «BALANCE SHAFT TIMING CHAIN»(ref-496097-S30846589402012082100000)
18. Chain Sprocket Installed location «CAMSHAFT TIMING CHAIN ASSEMBLY OVERVIEW»(ref-496097-S33722363212012082100000)
19. Guide Rail For the balance shaft timing chain
20. Guide Pins 20 Nm

Scheme 117

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

Scheme 118

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

Scheme 119

Tighten with a new bolt as follows

Tighten to 10 Nm using a torque wrench.

Rotate the intermediate shaft sprocket.

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

Tighten to 25 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

CYLINDER HEAD ASSEMBLY OVERVIEW

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

Scheme 120

1. Cylinder Head Gasket Replace Installed position: the part number faces the cylinder head
2. Bolt 25 Nm
3. Transport Bracket
4. Bolt Tightening order «CYLINDER HEAD ASSEMBLY OVERVIEW»(ref-496097-S26513471012012082100000)
5. Cylinder Head Removing and installing, refer to «CYLINDER HEAD»(ref-496097-S36422039712012082100000) Check for distortion «CYLINDER HEAD ASSEMBLY OVERVIEW»(ref-496097-S26513471012012082100000)
6. Cylinder Head Bolt Replace Observe sequence for loosening «CYLINDER HEAD ASSEMBLY OVERVIEW»(ref-496097-S26513471012012082100000) Observe sequence for tightening «CYLINDER HEAD ASSEMBLY OVERVIEW»(ref-496097-S26513471012012082100000)
7. O-ring Replace Lubricate with engine oil
8. Sealing Plugs 5 Nm With ball head for the engine cover
9. Cap With gasket
10. O-ring Replace Lubricate with engine oil
11. Sealing Plugs
12. Bracket
13. Bolt 9 Nm
14. Heat Shield
15. Bolt 20 Nm
16. Bolt 20 Nm
17. To the Intake Manifold/Turbocharger
18. Ventilation Pipe
19. O-ring No replacement part
20. Gasket No replacement part
21. Engine Cover
22. Bolt Tightening order «CRANKCASE VENTILATION, TIGHTENING SEQUENCE»(ref-496097-S34765281802012082100000)
23. Crankcase Ventilation Observe sequence for tightening «CRANKCASE VENTILATION, TIGHTENING SEQUENCE»(ref-496097-S34765281802012082100000)
24. To Intake Manifold
25. Gasket No replacement part
26. Gasket Replace if damaged
27. Vacuum Pump Removing and installing, refer to «Removal and Installation»(ref-496088-S12722945322012082100000)
28. Bolt Tightening specifications, refer to «Removal and Installation»(ref-496088-S12722945322012082100000)
29. 9 Nm Engine code CBFA only
30. Secondary air injection (AIR) solenoid valve -N112- Engine code CBFA only
31. Gasket Replace Engine code CBFA only
32. Mounting plate
33. Bolt 9 Nm
34. Connecting piece
35. O-ring Replace Coat with coolant
36. Bolt 25 Nm
37. Transport Bracket
38. Bolt 9 Nm
39. Camshaft Position Sensor -G40
40. Partition Plate

Scheme 121

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

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

Scheme 122

Remove the bolts -arrows-.

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

Scheme 123

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

Tighten to 40 Nm using a torque wrench.

Tighten further 90° using a rigid wrench.

Tighten further 90° using a rigid wrench.

Tighten the bolts -arrows- to 8 Nm.

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

Scheme 124

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

1. Maximum permissible distortion: 0.05 mm

VALVETRAIN ASSEMBLY OVERVIEW

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

Scheme 125

1. Exhaust Valve Do not rework, only lapping is permitted Valve dimensions «VALVETRAIN ASSEMBLY OVERVIEW»(ref-496097-S10055778762012082100000) Check valve guides, refer to «VALVE GUIDES, CHECKING»(ref-496097-S22327725142012082100000)
2. Cylinder Head
3. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(ref-496097-S22327725142012082100000)
4. Valve Stem Seal Replacing: cylinder head installed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING»(ref-496097-S14929770092012082100000) , cylinder head removed, refer to «VALVE STEM SEALS WITH CYLINDER HEAR REMOVED, REPLACING»(ref-496097-S27582414932012082100000)
5. Valve Spring
6. Valve Spring Plate
7. Valve Retainers
8. Hydraulic Adjusting Element Do not interchange Lubricate contact surface
9. Exhaust Camshaft Removing and installing, refer to «CAMSHAFTS»(ref-496097-S26552718712012082100000) Check radial clearance using Plastigage (roller rocker lever removed) Radial play: 0.024 to 0.066 mm Run-out: maximum 0.04 mm
10. Cylinder Head Cover With integrated camshaft bearings Clean sealing surface, refacing is not permitted. Remove old sealant residue.
11. Bolt Replace Loosening «LOOSENING THE CYLINDER HEAD COVER»(ref-496097-S29653794542012082100000) Tightening order «CYLINDER HEAD COVER TIGHTENING SEQUENCE»(ref-496097-S05479925512012082100000)
12. O-ring Replace Coat with engine oil
13. Sealing Plugs
14. Intake Camshaft Removing and installing, refer to «CAMSHAFTS»(ref-496097-S26552718712012082100000) Check radial clearance using Plastigage (roller rocker lever removed) Radial play: 0.024 to 0.066 mm Run-out: maximum 0.04 mm
15. Cap Replace Removing: with the cylinder head cover installed, pierce through one side of the cover with an awl and pry it out Installing «CAMSHAFTS»(ref-496097-S26552718712012082100000)
16. Intake Valve Do not rework, only lapping is permitted Valve dimensions «VALVETRAIN ASSEMBLY OVERVIEW»(ref-496097-S10055778762012082100000) Check valve guides, refer to «VALVE GUIDES, CHECKING»(ref-496097-S22327725142012082100000)

Scheme 126

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

Scheme 127

Replace bolts.

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

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

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

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

Scheme 128

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