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2.0L - Cylinder Head, Valvetrain - Engine Code(s): Bpy: Overview Audi A3 8P facelift

Mechanical 14 illustrations ~1525 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»(ref-496096-S34213479582012082100000) 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»(ref-496061-S08412897882012082100000)
  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»(ref-496100-S38917956182012082100000)
  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»(ref-496096-S34213479582012082100000) Installing (adjusting valve timing), refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(ref-496096-S34213479582012082100000)
  22. Lower Toothed Belt Guard
  23. Engine Support Removing: Toothed belt, removing and installing, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(ref-496096-S34213479582012082100000)
  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»(ref-496061-S08412897882012082100000)
  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»(ref-496100-S38917956182012082100000)
  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»(ref-496096-S37765636672012082100000)
  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»(ref-496096-S33356190032012082100000)
  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»(ref-496096-S31171869042012082100000)
  4. 4 - Cylinder Head Reworking dimension (Scheme 122)
  5. 5 - Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(ref-496096-S16520193422012082100000)
  6. 6 - Valve Stem Seal
  7. 7 - Valve Spring
  8. 8 - Top Valve Spring Retainer Replace, refer to «VALVE STEM SEALS, CYLINDER HEAD INSTALLED»(ref-496096-S33398931002012082100000) or «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(ref-496096-S37710693242012082100000)
  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»(ref-496096-S31737446332012082100000) 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»(ref-496096-S16520193422012082100000)
  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»(ref-496096-S16520193422012082100000)
  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

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