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3.2L - Cylinder Head, Valvetrain - Engine Code(s): Bub & Cbra: Overview Audi A3 8P facelift

Mechanical 17 illustrations ~1754 words

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

Scheme 1: CYLINDER HEAD COMPONENT OVERVIEW
Scheme 1: CYLINDER HEAD COMPONENT OVERVIEW
  1. Cylinder Head Gasket Metal gasket Replace After replacing, change coolant and engine oil
  2. Cylinder Head Removal, refer to «CYLINDER HEAD, REMOVING»(ref-496095-S22802314482012082100000) Check for distortion (Scheme 5) Installation, refer to «CYLINDER HEAD, INSTALLING»(ref-496095-S18184587582012082100000) 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»(ref-496095-S18386597162012082100000)
  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»(ref-496084-S25473696942012082100000)

Scheme 2

Scheme 2
Scheme 2

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

Scheme 3

Scheme 3
Scheme 3

Loosen the bolts in sequence -1 to 20-.

Scheme 4

Scheme 4
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

Scheme 5
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

Scheme 6: TIMING CHAIN COVERS ASSEMBLY OVERVIEW
Scheme 6: TIMING CHAIN COVERS ASSEMBLY OVERVIEW
  1. 4 - Bolt Tightening specifications (Scheme 7)
  2. 5 - Thermostat Housing Removal and installation, refer to «COOLANT THERMOSTAT HOUSING»(ref-496050-S00893185972012082100000)
  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»(ref-496095-S35617768752012082100000).
  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»(ref-496095-S02345157352012082100000)
  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»(ref-496095-S41365313312012082100000)
  16. 19 - Bolt Tightening specifications and tightening sequence (Scheme 7)
  17. 20 - Cylinder Head Gasket Clean holes and fill with sealant «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000)
  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

Scheme 7
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

Scheme 8: TIMING CHAIN COMPONENT OVERVIEW
Scheme 8: TIMING CHAIN COMPONENT OVERVIEW
  1. Control Housing Removal and installation, refer to «CAMSHAFTS»(ref-496095-S18861457852012082100000) 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»(ref-496095-S02345157352012082100000) Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(ref-496095-S14105691352012082100000)
  4. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000)
  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»(ref-496095-S02345157352012082100000)
  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»(ref-496095-S14105691352012082100000)
  13. Camshaft Timing Chain Sprocket Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(ref-496095-S14105691352012082100000)
  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»(ref-496095-S14105691352012082100000)
  18. Timing Mechanism Drive Chain Guide Rail Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(ref-496095-S14105691352012082100000)
  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»(ref-496095-S02345157352012082100000)
  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»(ref-496095-S02345157352012082100000) 60 Nm plus an additional 90° ( 1 / 4 ) turn.
  24. Camshaft Timing Chain Guide Rail Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000)
  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

Scheme 9
Scheme 9

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

CAUTIONRisk of damaging timing chain. Do not mark chain with punch, notch or something similar.

Scheme 10

Scheme 10
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

Scheme 11: VALVETRAIN COMPONENT OVERVIEW
Scheme 11: VALVETRAIN COMPONENT OVERVIEW
  1. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000)
  2. Bolt Replace Counter-hold camshaft using fork wrench SW 32 for removal and installation «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000) Tightening specifications item -23- «TIMING CHAIN COMPONENT OVERVIEW»(ref-496095-S41365313312012082100000)
  3. Camshaft Adjuster, Intake Side Identification: "24E" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(ref-496095-S02345157352012082100000)
  4. Control Housing Removal and installation, refer to «CAMSHAFTS»(ref-496095-S18861457852012082100000) 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»(ref-496095-S22405753462012082100000) Replacing with the cylinder head removed, refer to «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(ref-496095-S32886213062012082100000)
  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»(ref-496095-S18861457852012082100000)
  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»(ref-496095-S30959252702012082100000) Removal and installation, refer to «CAMSHAFTS»(ref-496095-S18861457852012082100000) 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»(ref-496095-S30959252702012082100000) Removal and installation, refer to «CAMSHAFTS»(ref-496095-S18861457852012082100000) 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»(ref-496095-S30959252702012082100000) 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»(ref-496095-S30959252702012082100000) Lubricate contact surface
  17. Cylinder Head Check valve guides, refer to «VALVE GUIDES, CHECKING»(ref-496095-S31220433972012082100000) Reface valve seat, refer to «REFACING VALVE SEATS»(ref-496095-S22304703142012082100000)
  18. Intake Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(ref-496095-S32658221982012082100000) Check valve guides, refer to «VALVE GUIDES, CHECKING»(ref-496095-S31220433972012082100000) Refacing valve seats, refer to «REFACING VALVE SEATS»(ref-496095-S22304703142012082100000)
  19. Exhaust Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(ref-496095-S32658221982012082100000) Check valve guides, refer to «VALVE GUIDES, CHECKING»(ref-496095-S31220433972012082100000) Reface valve seats, refer to «REFACING VALVE SEATS»(ref-496095-S22304703142012082100000)
  20. Bolt 8 Nm

Scheme 12

Scheme 12
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

Scheme 13
Scheme 13

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

Scheme 14

Scheme 14
Scheme 14
  1. Tops of intake and exhaust camshaft bearing caps -arrow A- face toward outside.

Scheme 15

Scheme 15
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

Scheme 16
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

Scheme 17
Scheme 17

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

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