2.0l - Cylinder Head, Valvetrain - Engine Code(s): Caeb (avant) Audi A4 B8

CYLINDER HEAD, SCREWDRIVER ACCESS

Screwdriver Access

Camshafts with screwdriver access have notches -arrows- in the camshafts.

Scheme 367

Camshafts without screwdriver access do not have notches in the camshafts.

To check, turn the plugs -arrows- 90° counter clockwise in the direction of the -arrow- and remove them.

Scheme 368

Scheme 369

1. O-ring Replace Oil before assembling
2. Guide Tube for Oil Dipstick
3. Bolt 9 Nm
4. Bolt 9 Nm
5. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Camshaft Adjustment Valve 1 -N205»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__camshaft-adjustment-valve-1-n205)
6. Seal Oil before assembling Replace if damaged
7. Bolt Tightening sequence (Scheme 370)
8. Upper Timing Chain Cover Removing and installing (Scheme 370)
9. Gasket Replace if damaged
10. O-ring Replace Oil before assembling
11. Alignment Pins Centering the cover
12. Lower Timing Chain Cover Replace, refer to «LOWER TIMING CHAIN COVER»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__lower-timing-chain-cover)
13. Bolt Replace Tightening sequence with 15 bolts (Scheme 371)Tightening sequence with 8 bolts (Scheme 372)
14. Shaft Seal For the vibration damper Removing and installing, refer to «VIBRATION DAMPER SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__vibration-damper-shaft-seal)
15. Sealing Plugs Replace

Scheme 370

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

Tighten the bolts to 9 Nm.

Scheme 371

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

1. Tighten the bolts to 8 Nm.

2. Tighten the bolts an additional 45°.

Scheme 372

Tighten the bolts -1 through 8- in 2 stages in the sequence shown

1. Tighten the bolts to 4 Nm.

2. Tighten the bolts an additional 45°.

Scheme 373

1. Bolt 9 Nm
2. Chain Tensioner Is under tension Disconnect the locking pinT40011 before removing
3. Timing Chain Tensioning Rail
4. Guide Pins 20 Nm
5. Bolt 9 Nm
6. Control Valve 35 Nm Left thread Remove using the assembly tool T10352 or assembly tool T10352/1 depending on the version
7. Bolt 20 Nm + 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 Pins 20 Nm
15. Three Stage Chain Sprocket Crankshaft Installed location (Scheme 374)

Scheme 374

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

Scheme 375

1. Bolt 9 Nm Replace
2. Balance Shaft Exhaust side Must be replaced after removing Lubricate the bearing with engine oil Removing and installing, refer to «EXHAUST CAMSHAFT BALANCE SHAFT»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__exhaust-camshaft-balance-shaft).
3. Pipe for the Balance Shaft Installed location (Scheme 376)
4. Chain Tensioner 85 Nm
5. Cylinder Block
6. Balance Shaft Intake side Must be replaced after removing Lubricate the bearing with engine oil Removing and installing, refer to «INTAKE CAMSHAFT BALANCE SHAFT»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__intake-camshaft-balance-shaft).
7. O-ring Lubricate with engine oil
8. Mounting Pin Lubricate with engine oil Installed location (Scheme 377)
9. Intermediate Sprocket The intermediate sprocket must be replaced if the bolt is loosened.
10. Bolt Replace 9 Nm
11. Washer
12. Bolt Replace The intermediate sprocket must be replaced if the bolt is loosened. Tightening sequence (Scheme 378)
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 and installing, refer to «BALANCE SHAFT TIMING CHAIN»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__balance-shaft-timing-chain)
18. Three Stage Chain Sprocket Installed location (Scheme 374)
19. Guide Rail For the balance shaft timing chain
20. Guide Pins 20 Nm

Scheme 376

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

Scheme 377

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 378

Tighten with a new bolt as follows

Tighten to 10 Nm using a torque wrench.

Turn the intermediate sprocket.

The intermediate 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 OVERVIEW, WITH SCREWDRIVER ACCESS

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. The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Scheme 379

1. Cylinder Head Gasket Replace Note installation position: Parts number to cylinder head
2. Bolt 25 Nm
3. Transport Bracket
4. Bolt Tighten in 2 stages: -- Tighten to 8 Nm. -- Tighten 90° further using a rigid wrench.
5. Cylinder Head Removing and installing, refer to «CYLINDER HEAD WITH WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__cylinder-head-with-wrench-clearance) Check for distortion (Scheme 381)
6. Cylinder Head Bolt Replace Follow the procedure when loosening. Follow the procedure when tightening. (Scheme 471) Tighten in 3 stages: Tighten to 40 Nm. Tighten 90° further using a rigid wrench. Tighten 90° further using a rigid wrench.
7. O-ring Replace Coat with engine oil
8. Camshaft Adjuster Actuator
9. Bolt 5 Nm
10. O-ring Replace Lubricate with engine oil
11. Sealing Plugs 5 Nm With ball head for the engine cover
12. Cap With gasket
13. O-ring Replace Lubricate with engine oil
14. Sealing Plugs
15. To the Intake Manifold
16. Heat Shield
17. Screw 20 Nm
18. Bolt 20 Nm
19. To the Intake Manifold/Turbocharger
20. Ventilation Pipe
21. O-ring No replacement part
22. Gasket No replacement part
23. Engine Cover
24. Bolt Tightening sequence (Scheme 380)
25. Crankcase Ventilation
26. Gasket No replacement part
27. Gasket Replace if damaged
28. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical-hydraulic/#hydraulic-components-brake-system-avant__removal-and-installation)
29. Bolt Tightening specifications, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/mechanical-hydraulic/#hydraulic-components-brake-system-avant__description-and-operation)
30. Connecting Piece
31. Mounting Plate
32. Bolt 9 Nm
33. O-ring Replace Coat with coolant
34. Transport Bracket
35. Bolt 25 Nm
36. Bolt 9 Nm
37. Camshaft Position Sensor -G40
38. Partition Plate
39. O-ring Replace Lubricate with engine oil

Crankcase Ventilation, Tightening Sequence

Scheme 380

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 sequence -1 to 10-.

Checking Cylinder Head for Distortion

Scheme 381

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

1. Max. permissible distortion: 0.05 mm

CYLINDER HEAD OVERVIEW, WITHOUT SCREWDRIVER ACCESS

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. The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

1. Cylinder Head Gasket Replace Note installation position: Parts number to cylinder head
2. Bolt 25 Nm
3. Transport strap
4. Bolt Replace Follow the procedure when loosening. (Scheme 382) Follow the procedure when tightening. (Scheme 383)
5. Cylinder Head Removing and installing, refer to «CYLINDER HEAD WITHOUT WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__cylinder-head-without-wrench-clearance) Check for distortion see scheme 18
6. Cylinder Head Bolt Replace Follow the procedure when loosening. (Scheme 382) Follow the procedure when tightening. (Scheme 383)
7. O-ring Replace Coat with engine oil
8. Camshaft Adjuster Actuator
9. Bolt 5 Nm
10. O-ring Replace Lubricate with engine oil
11. Sealing Plugs 5 Nm With ball head for the engine cover
12. Cap With gasket
13. O-ring Replace Lubricate with engine oil
14. Sealing Plugs
15. To the Intake Manifold
16. Heat Shield
17. Bolt 20 Nm
18. Bolt 20 Nm
19. To the Intake Manifold/Turbocharger
20. Ventilation Pipe
21. O-ring No replacement part
22. Gasket No replacement part
23. Engine Cover
24. Bolt Tightening sequence see scheme 17
25. Crankcase Ventilation
26. Gasket No replacement part
27. Gasket Replace if damaged
28. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/mechanical-hydraulic/#hydraulic-components-brake-system-avant__removal-and-installation)
29. Bolt Tightening specifications, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/mechanical-hydraulic/#hydraulic-components-brake-system-avant__description-and-operation)
30. Connecting Piece
31. Mounting Plate
32. Bolt 9 Nm
33. O-ring Replace Coat with coolant
34. Transport Strap
35. Bolt 25 Nm
36. Bolt 9 Nm
37. Camshaft Position Sensor -G40
38. Partition Plate
39. O-ring Replace Lubricate with engine oil

Crankcase Ventilation, Tightening Sequence

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.

Checking Cylinder Head for Distortion

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

1. Max. permissible distortion: 0.05 mm

Loosening Cylinder Head

Scheme 382

Remove the bolts -arrows-.

Loosen the cylinder head bolts in sequence -1 through 10

Cylinder Head Tightening Sequence

Scheme 383

Tighten the cylinder head bolts in -1 through 10- sequence.

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.
4. Tighten the bolts -arrows- to 8 Nm.
5. Tighten the bolts -arrows- 90° further using a rigid wrench.

VALVETRAIN OVERVIEW

Note. The cylinder head and the cylinder head cover must be replaced together. Do not start the engine for approximately 30 minutes after installing the camshafts. 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 the gaskets and seals.

Scheme 384

1. Exhaust Valve Do not rework, only lapping is permitted For the correct valve dimensions (Scheme 387)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valve-guides-checking)
2. Cylinder Head
3. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valve-guides-checking)
4. Valve Stem Seal Replace, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valve-stem-seals-with-cylinder-head) or «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valve-stem-seals-with-cylinder-head)
5. Valve Spring
6. Valve Spring Plate
7. Valve Retainers
8. Hydraulic Adjusting Element With roller rocker lever Do not interchange Lubricate contact surface
9. Exhaust Camshaft Removing and installing, refer to «CAMSHAFTS»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__camshafts) Check radial clearance using Plastigage (roller rocker lever removed) Radial clearance: 0.024 to 0.066 mm Run-out: max. 0.04 mm
10. Cylinder Head Cover With integrated camshaft bearings Clean sealing surface, reworking is not permitted. Remove old sealant residue.
11. Bolt Replace Loosening (Scheme 385)Tightening sequence (Scheme 386)
12. O-ring Replace Coat with engine oil
13. Camshaft Adjuster Actuator
14. Bolt 5 Nm
15. O-ring Replace Coat with engine oil
16. Sealing Plugs
17. Intake Camshaft Removing and installing, refer to «CAMSHAFTS»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__camshafts) Check radial clearance using Plastigage (roller rocker lever removed) Radial clearance: 0.024 to 0.066 mm Run-out: max. 0.04 mm
18. Cap Replace Removing with the cylinder head cover installed, pierce through one side of the cover with an awl and pry it out Installing (Scheme 483)
19. Intake Valve Do not rework, only lapping is permitted For the correct valve dimensions (Scheme 387)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valve-guides-checking)

Loosening Cylinder Head Cover

Scheme 385

Loosen the cylinder head cover in sequence -1 through 6-.

Cylinder Head Cover Tightening Sequence

Scheme 386

Replace the bolts.

1. Hand-tighten bolts in several steps in -1 to 6- sequence.
2. Tighten the bolts in a -1 to 6- sequence to 8 Nm using a torque wrench.
3. 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.

Valve Dimensions

Scheme 387

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

FASTENER TIGHTENING SPECIFICATIONS

Upper Timing Chain Cover - Tightening Sequence

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

Tighten the bolts to 9 Nm.

Lower Timing Chain Guard - Tightening Sequence for 15 Bolts

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

1. Tighten the bolts to 8 Nm.

2. Tighten the bolts an additional 45°.

Lower Timing Chain Guard - Tightening Sequence for 8 Bolts

Tighten the bolts -1 through 8- in 2 stages in the sequence shown

1. Tighten the bolts to 4 Nm.

2. Tighten the bolts an additional 45°.

Intermediate Shaft Sprocket Tightening Sequence

Tighten with a new bolt as follows

1. Tighten to 10 Nm using a torque wrench.

2. Rotate the intermediate shaft sprocket.

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

3. Tighten to 25 Nm using a torque wrench.

4. Tighten further 90° using a rigid wrench.

Crankcase Ventilation, Tightening Sequence

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 sequence -1 through 10-.

Cylinder Head Tightening Sequence

Tighten the cylinder head bolts in -1 through 10- sequence.

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.
4. Tighten the bolts -arrows- to 8 Nm.
5. Tighten the bolts -arrows- 90° further using a rigid wrench.

Cylinder Head Cover Tightening Sequence

Replace the bolts.

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

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

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

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

VALVE TIMING, CHECKING

Special tools and workshop equipment required

1. Dial Gauge 0-10 mm -VAS 6079

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN GUARD .

Remove the noise insulation. Refer to Description and Operation .

Turn the vibration damper, from underneath, in direction of engine rotation to Top Dead Center TDC.

Scheme 388

Note. Use a ratchet with a 24 mm socket to turn the vibration damper. Always turn vibration damper in direction of engine rotation to "TDC". Do not turn the vibration damper backward to get to TDC!

1. The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another -arrow-.
2. The markings -1- on the camshafts must point upward.

Measure the distance from the outer edge -1- to the marking -2- on the intake camshaft.

Scheme 389

1. Specified value: 61 to 64 mm.

Once the specified value is reached, measure the distance between the marking on the exhaust camshaft -3- and the marking on the intake camshaft -4-.

Scheme 390

1. Specified value: 124 to 126 mm.

Note. If one tooth has an offset, there will be a deviation of approximately 6 mm from the specified value. Install the timing chain once again if there is an offset.

POSITIONING ENGINE AT TDC WITH DIAL GAUGE 0-10 MM -VAS 6079

Special tools and workshop equipment required

1. Dial Gauge 0-10 mm -VAS 6079
2. Dial Gauge Adapter -T10170- or Dial Gauge Adapter -T10170 A

Scheme 391

Scheme 392

1. Remove timing chain upper cover
2. Turn the crankshaft with the socket SW 24 on the vibration damper in the direction of the engine rotation until the markings -arrows- are on top.
3. Remove the spark plug from cylinder 1.
4. Install the -T10170/A- all the way into the spark plug thread.
5. Insert the -VAS 6079- with the -T10170A/1- all the way and secure it with the locking nut -arrow-.
6. Turn the crankshaft slowly to maximum dial reading in the direction of the engine rotation. When the maximum dial reading is reached (Bottom Dead Center (BDC) of the meter) position the piston at Top Dead Center (TDC).

Note. Use a ratchet with a 24 mm socket to turn the vibration damper. Always turn vibration damper in direction of engine rotation to TDC. Do not turn the vibration damper backward to get to TDC!

COMPRESSION PRESSURE, CHECKING

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Ignition Coil Puller T40039
3. Compression Tester V.A.G 1763

Test Sequence

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

Remove the engine cover -arrows-.

Scheme 393

Remove the bolts on the ignition coil connector strip.

Release the connector -arrows- and disconnect all the connectors at the same time from the ignition coils.

Scheme 394

Remove the ignition coils with the T40039.

Scheme 395

Remove the spark plugs using a 3122 B.

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

Note. Using tester see operating Instructions.

Operate starter until tester shows no further pressure increase.

Compression Pressure

Install the spark plugs. Refer to MAINTENANCE PROCEDURES

Install the ignition coils with output stages. Refer to Removal and Installation .

Note. By separating the connections, Diagnostic Trouble Codes (DTCs) are stored to memory. After the test, check the DTC memory and erase, if necessary.

Check the Engine Control Module (ECM) DTC memory. Refer to vehicle diagnostic, tester under "Guided Fault Finding".

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

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

Test Sequence

Insert valve into guide. Valve stem end must be flush with the guide. Due to differences in valve stem diameter, make sure that only intake valves are used to check intake valve guides, and only exhaust valves are used to check exhaust valve guides.

Scheme 396

Determine tip clearance.

Wear Limit

Note. If wear limit is exceeded, measure again using new valves. If wear limit is still exceeded, replace cylinder head. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

CAMSHAFT ADJUSTMENT VALVE 1 -N205

Removing

Disconnect the connector from the camshaft adjustment valve 1 -1-.

Scheme 397

Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «TIMING CHAIN GUARDS, Camshaft Adjustment Valve 1 -N205- OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Note. Replace O-ring.

Coat the seal and the O-ring with engine oil.

UPPER TIMING CHAIN GUARD

Removing

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1.

Remove the bolts -1 through 5- and the timing chain guard upper section.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «TIMING CHAIN GUARDS, Camshaft Adjustment Valve 1 -N205- OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Note. Replace O-ring.

Coat the seal and the O-ring with engine oil.

Install the timing chain upper cover, tightening sequence. (Scheme 370)

Install the camshaft adjustment valve 1. Refer to Camshaft Adjustment Valve 1 -N205 .

LOWER TIMING CHAIN COVER

Special tools and workshop equipment required

1. Locking Tool T40098
2. Counter Hold Tool T10355
3. Thrust Piece T10368

Removing

Remove the front noise insulation. Refer to Description and Operation .

Remove the front bumper cover and bumper. Refer to Removal and Installation .

Install the lock carrier in service position. Refer to Description and Operation .

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Scheme 398

Secure the tensioner with the T40098.

Remove the bolt -1- and remove the ribbed belt tensioner from the accessory assembly bracket.

Remove ribbed belt.

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Scheme 399

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Remove vibration damper bolt using the T10355.

Remove the vibration damper.

Note. To avoid damaging the splines, only install the vibration damper bolt with the T10368.

Install the vibration damper bolt and T10368 again.

Scheme 400

Remove the idler roller -1-.

Remove the bolts -arrows- and remove the oil dipstick guide tube from the timing chain cover.

Scheme 401

Remove the bolts -1 through 15-.

Note. There may be 8 bolts installed, depending on the version.

Pry off the timing chain guard lower section

Installing

1. For the correct tightening specifications, refer to «TIMING CHAIN GUARDS, Camshaft Adjustment Valve 1 -N205- OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant)

1. Silicon sealant

Note. Note the expiration date of the silicone sealant. The cover must be installed within 5 minutes after the silicone sealant has been applied. Replace the bolts which are being tightened with an additional turn. Replace sealing rings, seals and self-locking nuts.

Remove any sealant residue on the cylinder block using a flat blade scraper.

Clean any oil or grease off the sealing surfaces.

Make sure both alignment bushings for centering the cover -arrows- are present.

Scheme 402

Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Scheme 403

Cover with 15 Bolts

Scheme 404

Apply the silicone sealant on the clean sealing surface of the new cover as illustrated.

1. Thickness of sealant bead: 2 to 3 mm

Cover with 8 Bolts

Scheme 405

Apply the silicone sealant on the clean sealing surface of the new cover as illustrated.

1. Thickness of sealant bead: 2 to 3 mm.

Note. The cover must be installed within 5 minutes after the silicone sealant has been applied. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

Immediately attach the cover and tighten the bolts

1. Cover with 15 bolts (Scheme 371)
2. Cover with 8 bolts (Scheme 372)

Note. After installing cover, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

Install vibration damper. Refer to VIBRATION DAMPER .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

Install the service position. Refer to Description and Operation .

Install the bumper and front bumper cover. Refer to Removal and Installation .

Install the front noise insulation. Refer to Description and Operation .

Check the oil level. Refer to MAINTENANCE PROCEDURES

VIBRATION DAMPER SHAFT SEAL

Special tools and workshop equipment required

1. Locking Tool T40098
2. Counter Hold Tool T10355
3. Thrust Piece T10368
4. Pulling Hook T40274
5. Thrust Piece T10354
6. Pulling Hook T20143

Removing

Remove the front noise insulation. Refer to Description and Operation .

Remove the coolant fan electrical connector -1- from the bracket and disconnect it by sliding the retainer back -arrow- and pressing the release down.

Scheme 406

Free up the electrical wiring harness to the radiator fan control module.

Disconnect electrical connectors -2- and -3-.

Scheme 407

Remove the bolt -arrow- and the coolant fan control module -1-.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Secure the tensioner with the T40098.

Remove ribbed belt from vibration damper ribbed belt pulley.

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Remove vibration damper bolt using the T10355.

Remove the vibration damper and attach the T10368.

Scheme 408

Remove the shaft seal with the T40274.

Scheme 409

Installing

1. For the correct tightening specifications, refer to «RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-avant) .

Clean running and sealing surface.

Remove the T10368.

Push the sealing ring -arrow- using the T10354 and the vibration damper bolt in all the way.

Scheme 410

Note. Replace the vibration damper bolt with an O-ring.

Assemble in reverse order of disassembly. When doing this note the following

Install vibration damper. Refer to VIBRATION DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

CAMSHAFT TIMING CHAIN (WITHOUT NEW TOOLS)

Special tools and workshop equipment required

1. Locking Tool T40098
2. Counter Hold Tool T10355
3. Assembly Tool T10352 and Assembly Tool T10352/1
4. Locking Pin T40011

Removing

Remove the front bumper cover and the bumper. Refer to Removal and Installation .

Install the lock carrier in service position. Refer to Description and Operation .

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN GUARD .

Scheme 411

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Scheme 412

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
2. The markings -1- on the camshafts must point upward.

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Press the oil pump chain tensioner in the direction of the -arrow- and secure it with the T40011.

Scheme 413

Remove the oil pump chain tensioner -1-.

Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner in the direction of -arrow 1-.

Scheme 414

Press the timing chain tensioning rail in the direction of -arrow 2- and secure it with the T40011.

Remove the camshaft timing chain from the cylinder head.

Note. The intake camshaft switches in the engine direction of rotation.

Remove the timing chain tensioning rail -2-.

Scheme 415

Remove the guide rail for the camshaft timing chain -1-.

Remove the timing chain.

Installing

1. Tightening specifications, refer to «CAMSHAFT TIMING CHAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Note. The following must be performed in one sequence. A second technician is required for this. The painted links of the timing chain must be positioned on the markings on the chain sprockets. Hold the wrench tight until the tensioning rail is installed.

Mount the timing chain on the exhaust camshaft.

Mount the timing chain on the crankshaft.

Turn the intake camshaft using the wrench in the direction of the -arrow- and mount the timing chain.

Scheme 416

Install the timing chain tensioning rail and tighten the bolt -2-.

Install the camshaft timing chain guide rail and tighten the bolts -1-.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011.

Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

Install the control valve. See item 6 in (Scheme 373).

Assemble in reverse order of disassembly. When doing this note the following

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

Install the lock carrier in service position. Refer to Description and Operation .

Install the bumper and front bumper cover. Refer to Removal and Installation .

CAMSHAFT TIMING CHAIN (WITH NEW TOOLS)

Special tools and workshop equipment required

1. Locking Tool T40098
2. Counter Hold Tool T10355
3. Assembly Tool T10352 and Assembly Tool T10352/1
4. Locking Pin T40011
5. Pry Lever T40243
6. Camshaft Locator T40271

Removing

Remove the front bumper cover and bumper. Refer to Removal and Installation .

Install the lock carrier in service position. Refer to Description and Operation .

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN GUARD .

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Rotate the vibration damper using the T10355 into the "TDC" position.

1. The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another -arrow-.
2. The markings -1- on the camshafts must point upward.

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Press the oil pump chain tensioner in the direction of the -arrow- and secure it with the T40011.

Remove the oil pump chain tensioner -1-.

Remove the bolts -arrows-.

Scheme 417

Two Different Chain Tensioners may be Installed Depending on the Version

Version 1

Scheme 418

Install the T40243 -arrows-.

Insert a scriber or a suitable screwdriver into the opening for the chain tensioner in the direction of the -arrow 1- to lift up the locking wedge for the chain tensioner, slowly press down the T40243 and hold it in the direction of the -arrow 2-.

Secure the chain tensioner using T40011.

Scheme 419

Version 2

Scheme 420

Install the T40243 -arrows-.

Press the chain tensioner locking ring -arrow- together and slowly press and hold the T40243 in the direction of the -arrow-.

Secure the chain tensioner with the T40267.

Scheme 421

All Versions

Remove the T40243.

Bolt the T40271/2 to the cylinder head and push the chain sprocket splines in the direction of the -arrow 2-. If necessary, turn the intake camshaft with a wrench in the direction of the -arrow 1-.

Scheme 422

Attach the T40271/1 to the cylinder head.

Scheme 423

Turn the exhaust camshaft with the wrench in the direction of the -arrow 1- and slide the T40271/1 in the chain sprocket splines in the direction of the -arrow 2-.

Remove the timing chain tensioning rail -2-.

Remove the guide rail for the camshaft timing chain -1-.

Remove the timing chain.

Installing

1. Tightening specifications, refer to «CAMSHAFT TIMING CHAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Scheme 424

Note. The painted links of the timing chain must be positioned on the markings on the chain sprockets.

Mount the timing chain on the intake camshaft.

Mount the timing chain on the exhaust camshaft.

Lay the timing chain on the crankshaft and hold it there.

Install the timing chain tensioning rail and tighten the bolt -2-.

Install the camshaft timing chain guide rail and tighten the bolts -1-.

Turn the exhaust camshaft in the direction of the -arrow 1-, slide out the camshaft locating tool T40271/1 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Scheme 425

Remove the camshaft locating tool T40271/1.

Turn the intake camshaft in the direction of the -arrow 1-, slide out the camshaft locating tool T40271/2 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Scheme 426

Remove the T40271/2.

Install the bolts -arrows- and tighten them.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011 or the T40267, depending on the version.

Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

Install the control valve -item 6- in (Scheme 373).

Assemble in reverse order of disassembly. Note the following

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

Install the service position. Refer to Description and Operation .

Install the bumper and front bumper cover. Refer to Removal and Installation .

BALANCE SHAFT TIMING CHAIN

Removing

Remove timing chain upper cover. Refer to UPPER TIMING CHAIN GUARD .

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Remove the camshaft timing chain tensioner -3-.

Remove the balance shaft chain tensioner -1-.

Scheme 427

Remove the tensioning rail -2-.

Remove the guide rail -3-.

Remove the guide rail -4-.

Remove the timing chain.

Installing

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Turn the intermediate sprocket/balance shaft to the marking -arrow-.

Note. The painted links of the timing chain must be positioned on the markings on the chain sprockets.

Mount the timing chain; the painted links of the timing chain must be positioned on the markings on the chain sprockets.

Scheme 428

Install the timing chain guide rail and tighten the bolts -4-.

Install the timing chain guide rail and tighten the bolts -3-.

Install the timing chain tensioning rail and tighten the bolt -2-.

Install the timing chain tensioner -1-.

Check the setting one more time.

Check the markings on the intermediate sprocket/balance shaft -arrow-.

Note. The marking on the intermediate sprocket/balance shaft is shown with the chain removed.

Assemble in reverse order of disassembly. When doing this note the following

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

INTAKE CAMSHAFT BALANCE SHAFT

Special tools and workshop equipment required

1. Puller T10394
2. Puller T10055

Removing

Note. The intake camshaft balance shaft must be replaced after removal.

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Remove upper timing chain cover. Refer to UPPER TIMING CHAIN GUARD .

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Remove the intermediate sprocket -1-.

Remove the bolt -2- on the intake camshaft balance shaft.

Scheme 429

Install the half shell T10394/1 from the T10394 and turn it upward in direction of -arrow-.

Scheme 430

Install the T10394 and push the sliding sleeve in direction of -arrow-.

Scheme 431

Install the T10055 into the T10394 and remove the balance shaft in direction of -arrow-.

Scheme 432

Installing

Note. Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be inserted into the cylinder block without forcing it in. If this is not the case, then the balance shaft must be installed cooled.

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

Lubricate the balance shaft bearing with engine oil.

Install the new intake camshaft shim and tighten the bolt -2-.

Replace the O-ring -1- and coat with engine oil.

Coat the mounting pin with engine oil and insert it. The alignment pin -arrow- for the mounting pin must engage in the hole in the cylinder block.

Mark the tooth face on the intermediate sprocket with paint -arrow-.

Scheme 433

Install the intermediate sprocket; the marking on the balance shaft must be between the markings on the tooth faces.

Tighten the intermediate sprocket bolt -1-: Tightening sequence (Scheme 378)

Check the markings on the intermediate sprocket/balance shaft -arrow-.

Assemble in reverse order of disassembly. When doing this note the following

Install the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

Replace the coolant pump drive seal. Refer to COOLANT PUMP DRIVE SEAL, REPLACING .

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

EXHAUST CAMSHAFT BALANCE SHAFT

Special tools and workshop equipment required

1. Puller T10394
2. Puller T10055

Removing

Note. The exhaust camshaft balance shaft must be replaced after removal.

Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN GUARD .

Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Remove the bolt -1- on the exhaust camshaft balance shaft.

Install the half shell T10394/1 from the T10394.

Scheme 434

Install the T10394 and push the sliding sleeve in direction of -arrow-.

Scheme 435

Install the T10055 into the T10394 and remove the balance shaft.

Scheme 436

Installing

Note. Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be inserted into the cylinder block without forcing it in. If this is not the case, then the balance shaft must be installed cooled.

1. Tightening specifications, refer to «BALANCE SHAFT TIMING CHAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant) .

Check the installation position of the pipe for the balance shaft -arrow-.

The pin -arrow- must engage in the groove.

Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

Lubricate the balance shaft bearing with engine oil.

Install the new exhaust camshaft balance shaft.

Before tightening the bolt -1- make sure the balance shaft lies level on the crankshaft.

Note. If the balance shaft is not level, then the pipe for the balance shaft must be installed again.

Assemble in reverse order of disassembly. When doing this note the following

Install the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN (WITH NEW TOOLS) .

Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the ribbed belt tensioning damper. Refer to RIBBED BELT TENSIONING DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

CYLINDER HEAD WITH WRENCH CLEARANCE

Note. Camshafts with screwdriver access have notches in the camshafts (Scheme 367)

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Assembly Tool T10352 and Assembly Tool T10352/1
3. Counter Hold Tool T10355
4. Locking Pin T40011
5. Drift T40196
6. Polydrive Bit and Drive Socket T10070
7. Engine Bung Set VAS 6122
8. Polydrive Bit and Drive Socket T10070
9. Pry Lever T40243
10. Camshaft Locator T40271
11. Spark Plug Removal Tool 3122 B

Removing

Note. During installation, cable ties must be installed at the same location. Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.

Remove the front noise insulation. Refer to Description and Operation .

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the engine cover -arrows-.

Remove the plenum chamber covers -1, 2 and 3-.

Scheme 437

Disconnect the vacuum connection -2- from the plenum chamber bulkhead by removing the vacuum hose -3- on the back side -arrow-.

Scheme 438

Remove the coolant hoses on the back of the cylinder head.

Disconnect fuel lines -1 and 2-.

Scheme 439

Remove the front bumper cover and the bumper. Refer to Removal and Installation .

Install the lock carrier in service position. Refer to Description and Operation .

Disconnect the connector -1- from the Mass Airflow (MAF) Sensor -G70-.

Scheme 440

Loosen the air intake hose -2-.

Remove the air filter housing upward -arrows-.

Loosen the hose clamps -arrows- and remove the air guide hose.

Scheme 441

Disconnect the following connectors.

Scheme 442

2 - Disconnect from Knock Sensor (KS) 1 -G61

3 - From the Intake Manifold Runner Control (IMRC) Valve -N316-, Fuel Pressure Sensor -G247- and the Camshaft Position (CMP) sensor -G40-.

4 - From the fuel injectors

5 - From the Throttle Valve Control Module -J338-.

6 - From the Intake Air Temperature (IAT) Sensor -G42-.

Disconnect the connector -2- and free up the wire.

Scheme 443

Remove the coolant line bracket -arrow-.

Scheme 444

Note. The engine is not shown in the illustrations that follow.

Remove the intake manifold bracket by removing the mounting nut -1- and bolt -2-.

Scheme 445

Disconnect the coolant hose -arrow-.

Scheme 446

Remove the bolts -1 and 2- and move the oil supply line to the side.

Scheme 447

Remove the bolt -3- and move the coolant line to the side.

Loosen the hose clamp -arrow-, pull off the air guide hose and move it to the side.

Scheme 448

Disconnect the connectors -1 and 4- from the oil pressure switch -F22- and the reduced oil pressure switch -F378-.

Scheme 449

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

Scheme 450

Remove the bolts -arrows- and then remove the turbocharger support.

Scheme 451

Remove the bolts -arrows- on the oil return line.

Scheme 452

Remove the nuts -arrows- and push the catalytic converter to the rear.

Scheme 453

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1 -N205-.

Remove the bolts -1 through 5- and the timing chain guard upper section.

Remove the bolts on the ignition coil connector strip.

Release the connector -arrows- and disconnect all the connectors at the same time from the ignition coils.

Remove the ignition coils with the T40039.

Remove the spark plugs using a 3122 B.

Disconnect the hose for the crankcase ventilation - 1 -.

Scheme 454

Remove the bolts -arrows- and then remove the crankcase ventilation from the hose -2- in direction of -arrow-.

Disconnect the connectors -arrows- from the camshaft adjuster actuators --.

Scheme 455

Remove the camshaft adjuster actuators -- -arrows-.

Scheme 456

Turn the sealing plug -arrows- counterclockwise 90° in the direction of the -arrow- and remove it.

Scheme 457

Remove the ball head -1 and 2-.

Remove the cap.

Rotate the vibration damper using the T10355 to "TDC" position.

1. The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite of one another -arrow-.
2. The markings -1- on the camshafts must point upward.

Remove the cylinder head bolts -1 and 2- with the T10070.

Scheme 458

Scheme 459

Install the T40196 as illustrated.

Turn the crankshaft 4 complete turns in the direction of engine rotation.

Remove the T40196.

Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Remove the bolts -arrows- and remove the bearing bracket.

Rotate the vibration damper using the T10355 into the "TDC" position.

1. The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another -arrow-.
2. The markings -1- on the camshafts must point upward.

Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

Scheme 460

In addition, mark the camshaft timing chain to the camshaft timing chain guide rail -2- with a permanent marker.

Remove the plug -arrow-.

Scheme 461

Remove the bolts -arrows-.

Remove the bolt -arrow-.

Scheme 462

Two Different Chain Tensioners may be Installed Depending on the Version

Version 1

Install the T40243 -arrows-.

Insert a scriber or a suitable screwdriver into the opening for the chain tensioner in the direction of the -arrow 1- to lift up the locking wedge for the chain tensioner, slowly press down the T40243 and hold it in the direction of the -arrow 2-.

Secure the chain tensioner using T40011.

Version 2

Install the T40243 -arrows-.

Press the chain tensioner locking ring -arrow- together and slowly press and hold the T40243 in the direction of the -arrow-.

Secure the chain tensioner with the T40267.

All Versions

Remove the T40243.

Bolt the T40271/2 to the cylinder head and push the chain sprocket splines in the direction of the -arrow 2-. If necessary, turn the intake camshaft with a wrench in the direction of the -arrow 1-.

Remove the bolt -1- and guide the tensioning rail -2- downward.

Scheme 463

Attach the camshaft locating tool T40271/1 to the cylinder head.

Turn the exhaust camshaft with the wrench in the direction of the -arrow 1- and slide the camshaft locating toolT40271/1 in the chain sprocket splines in the direction of the -arrow 2-.

Remove the upper guide track -1- by unlocking the latch with a screwdriver and pushing the guide track forward.

Scheme 464

Remove camshaft timing chain from chain sprockets.

Remove the bolts -arrows-.

Scheme 465

Remove the cylinder head bolts with the T10070 in the following sequence: -1 through 8-.

Note. Make sure all wires and cables are disconnected. Pay attention to the tension and guide tracks when lifting the cylinder head.

Remove the cylinder head.

Lay the cylinder head on a soft surface, such as foam.

Installing

1. Tightening specifications, refer to «CYLINDER HEAD OVERVIEW, WITH WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__cylinder-head-overview-with-screwdriver-access) .

Note. Replace the bolts which are being tightened with an additional turn. Replace self-locking nuts, sealing rings, seals and O-rings. If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshafts. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps of the same type as those equipped by the factory. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

When Using a New Cylinder Head

Mark the camshaft sprocket to the T40271/1 and the T40271/2 -arrow-.

Turn the intake camshaft with a wrench in the direction of the -arrow 1-, slide the T40271/2 out of the chain sprocket splines if the direction of the -arrow 2- and bring the camshaft into the rest position.

Scheme 466

Remove the T40271/2.

Turn the exhaust camshaft with a wrench in the direction of the -arrow 1-, slide the T40271/1 out of the chain sprocket splines if the direction of the -arrow 2- and bring the camshaft into the rest position.

Scheme 467

Remove the T40271/1.

Transfer the self-made markings from the old camshafts to the new camshafts.

Attach the T40271/2 to the cylinder head.

Scheme 468

Turn the intake camshaft in the direction of the -arrow 1- until the markings -3- align with the T40271/2.

Slide the T40271/2 into the chain sprocket splines in the direction of the -arrow 2-.

Attach the T40271/1 to the cylinder head.

Scheme 469

Turn the exhaust camshaft in the direction of the -arrow 1- until the markings -3- align with the T40271/1.

Slide the T40271/1 into the chain sprocket splines in the direction of the -arrow 2-.

All

Set cylinder head gasket in place.

Scheme 470

1. Pay attention to centering pins in cylinder block -arrows-.
2. Observe cylinder head seal location, identification: The part number must be visible from the intake side.

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

Position the cylinder head.

Install the bolts -1 through 8-.

Scheme 471

Install the cylinder head bolts in the following sequence -1 through 8- with the T10070 and tighten them all together in 3 stages -item 6- in (Scheme 379).

Tighten the bolts -arrows- in two steps -item 4- in (Scheme 379).

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

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

1. The notch on the vibration damper must line up with the -arrow- marking on the timing chain lower cover.

Position the markings on the chain links -arrows- at the chain sprockets -1- to install the camshaft timing chain.

Scheme 472

Install the upper glide track -2-.

Turn the exhaust camshaft in the direction of the -arrow 1-, slide out the T40271/1 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Remove the T40271/1.

Move the tensioning rail -2- up and install the bolt -1-.

Turn the intake camshaft in the direction of the -arrow 1-, slide out the T40271/2 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Remove the T40271/2.

Check the valve timing. The camshaft timing chain and cylinder head -arrows- must align with the markings on the chain sprocket -1-.

Scheme 473

The markings for the camshaft timing chain and the camshaft timing chain glide track -2- must be opposite one another.

The notch on the vibration damper must be opposite the marking on the lower section of the timing chain guard -3-.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011 or the T40267, depending on the version.

Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

Install the bolt -arrow-.

Install the control valve -item 6- in (Scheme 373).

Install the T40196 as illustrated.

Scheme 474

Turn the crankshaft 4 complete turns in the direction of engine rotation.

Remove the T40196.

Install the bolts -1 and 2-.

Install the cylinder head bolts in the following sequence -1 and 2- with the T10070 and tighten them all together in 3 stages -item 6- in (Scheme 379).

Further assembly is performed in the reverse order of removal, thereby observing the following

Change the engine oil. Refer to MAINTENANCE PROCEDURES

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Replace coolant. Refer to COOLANT, DRAINING AND FILLING .

CYLINDER HEAD WITHOUT WRENCH CLEARANCE

Note. Camshafts without screwdriver access do not have notches in the camshafts (Scheme 367)

Special tools and workshop equipment required

1. Engine Bung Set VAS 6122
2. Polydrive Bit and Drive Socket T10070
3. Spark Plug Removal Tool 3122 B

Removing

Note. During installation, cable ties must be installed at the same location. Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.

Remove the camshafts. Refer to CAMSHAFTS .

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the plenum chamber covers -1, 2 and 3-.

Disconnect the vacuum connection -2- from the plenum chamber bulkhead by remove the vacuum hose -3- on the back side -arrow-.

Remove the coolant hoses on the back of the cylinder head.

Disconnect fuel lines -1 and 2-.

Loosen the hose clamps -arrows- and remove the air guide hose.

Disconnect the following connectors.

2 - Disconnect from Knock Sensor (KS) 1 -G61

3 - From the Intake Manifold Runner Control (IMRC) Valve -N316-, Fuel Pressure Sensor -G247- and the Camshaft Position (CMP) Sensor -G40-.

4 - From the fuel injectors

5 - From the Throttle Valve Control Module -J338-.

6 - From the Intake Air Temperature (IAT) Sensor -G42-.

Disconnect the connector -2- and free up the wire.

Remove the coolant line bracket -arrow-.

Note. The engine is not shown in the illustrations that follow.

Remove the intake manifold bracket by removing the mounting nut -1- and bolt -2-.

Disconnect the coolant hose -arrow-.

Remove the bolts -1 and 2- and move the oil supply line to the side.

Remove the bolt -3- and move the coolant pipe to the side.

Loosen the hose clamp -arrow-, pull of the air guide hose and move it to the side.

Disconnect the connectors -1 and 4- from the oil pressure switch -F22- and the reduced oil pressure switch -F378-.

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

Remove the bolts -arrows- and then remove the turbocharger support.

Remove the bolts -arrows- on the oil return line.

Remove the nuts -arrows- and push the catalytic converter to the rear.

Remove the spark plugs using a 3122 B.

Remove the bolts -arrows-.

Remove the cylinder head bolts in sequence -1 through 10- using the T10070.

Note. Make sure all wires and cables are disconnected! Pay attention to the tension and guide tracks when lifting the cylinder head.

Remove the cylinder head.

Lay the cylinder head on a soft surface, such as foam.

Installing

1. For the correct tightening specifications, refer to «CYLINDER HEAD WITHOUT WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__cylinder-head-without-wrench-clearance) .

Note. Replace the bolts which are being tightened with an additional turn. Replace sealing rings, seals and self-locking nuts. Note different sealant for cylinder head sealing surfaces and bolts. If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshafts. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Set cylinder head gasket in place.

1. Pay attention to centering pins in cylinder block -arrows-.
2. Observe cylinder head seal location, identification: The part number must be visible from the intake side.

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

Set cylinder head in place.

Insert cylinder head bolts and tighten by hand.

Cylinder head tightening sequence. (Scheme 383)

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

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Further installation is performed in the reverse order of removal, thereby observing the following

Install the camshafts. Refer to CAMSHAFTS .

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Change the engine oil. Refer to MAINTENANCE PROCEDURES

Replace coolant. Refer to COOLANT, DRAINING AND FILLING .

CAMSHAFTS

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Assembly Tool T10352/1
3. Counter hold tool T10355
4. Locking Pin T40011
5. Thrust Piece T10174
6. Drift T40196
7. Spacers T40191
8. Pry Lever T40243
9. Camshaft Locator T40271

Removing

Note. The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked. The camshaft bearings are integrated in the cylinder head or cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover. If the cylinder head cover was removed, then the cap -item 18 - in VALVETRAIN OVERVIEW must be replaced. During installation, cable ties must be installed at the same location.

Install the lock carrier in service position. Refer to Description and Operation .

Remove the engine cover -arrows-.

Remove both the lower air guide and the air guide hose.

Disconnect the connector -1- from the Mass Airflow (MAF) Sensor -G70-.

Loosen the air intake hose -2-.

Remove the air filter housing upward -arrows-.

Remove the bolts on the ignition coil connector strip.

Disconnect the connectors -arrows- from the camshaft adjuster actuators.

Release the connector -arrows- and disconnect all the connectors at the same time from the ignition coils.

Remove the ignition coils with the T40039.

Remove the camshaft adjuster actuators -arrows-.

Disconnect the hose for the crankcase ventilation -1-.

Remove the bolts -arrows- and then remove the crankcase ventilation from the hose -2- in direction of -arrow-.

Disconnect the wire -arrows-.

Scheme 475

Disconnect the connector -1- from the camshaft position sensor -G40-.

Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Remove the bolts -arrows- and then the camshaft adjustment valve 1 -N205-.

Remove the bolts -1 through 5- and the timing chain guard upper section.

Remove the control valve using the T10352/1 in the direction of the -arrow-.

Scheme 476

Remove the bolts -arrows- and remove the bearing bracket.

Rotate the vibration damper using the T10355 to "TDC" position.

1. The notch on the vibration damper and the marking on the timing chain guard lower section must be opposite one another -arrow-.
2. The markings -1- on the camshafts must point upward.

Scheme 477

Install the T40196 as illustrated.

Turn the crankshaft 2 complete turns in the direction of engine rotation.

Note. The engine back at Top Dead Center (TDC).

Remove the T40196.

Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

In addition, mark the camshaft timing chain to the camshaft timing chain guide rail -2- with a permanent marker.

Remove the plug -arrow-.

Remove the bolts -arrows-.

Remove the bolt -arrow-.

Two different chain tensioners may be installed depending on the version

Version 1

Install the T40243 -arrows-.

Insert a scriber or a suitable screwdriver into the opening for the chain tensioner in the direction of the -arrow 1- to lift up the locking wedge for the chain tensioner, slowly press down the T40243 and hold it in the direction of the -arrow 2-.

Secure the chain tensioner using T40011.

Version 2

Install the T40243 -arrows-.

Press the chain tensioner locking ring -arrow- together and slowly press and hold the T40243 in the direction of the -arrow-.

Secure the chain tensioner with the T40267.

Remove the T40243.

Bolt the camshaft locating tool T40271/2 to the cylinder head and push the chain sprocket splines in the direction of the -arrow 2-. If necessary, turn the intake camshaft with a wrench in the direction of the -arrow 1-.

Remove the bolt -1- and guide the tensioning rail -2- downward.

Attach the camshaft locating tool T40271/1 to the cylinder head.

Turn the exhaust camshaft with the wrench in the direction of the -arrow 1- and slide the T40271/1 in the chain sprocket splines in the direction of the -arrow 2-.

Mark the camshaft sprocket to the T40271/1 and the T40271/2 -arrow-.

Remove the upper guide track -1- by unlocking the latch with a screwdriver and pushing the guide track forward.

Remove camshaft timing chain from chain sprockets.

Turn the intake camshaft with a wrench in the direction of the -arrow 1-, slide the T40271/2 out of the chain sprocket splines if the direction of the -arrow 2- and bring the camshaft into the rest position.

Turn the exhaust camshaft with a wrench in the direction of the -arrow 1-, slide the T40271/1 out of the chain sprocket splines if the direction of the -arrow 2- and bring the camshaft into the rest position.

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

Remove vacuum pump. Refer to Removal and Installation .

Remove the cylinder head cover bolts in -1 to 6- sequence.

Remove the cylinder head cover.

Remove the camshafts.

Installing

1. Tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-avant__valvetrain-overview) .

Note. Sealing surfaces must be completely free of oil and grease. The pistons must not be positioned at TDC. Make sure that all roller cam followers make contact correctly on valve stem ends.

Remove any sealant residue on the cylinder head using the flat blade scraper.

Remove any seal out of the groove in the cylinder head cover as well as from any sealing surface using, for example, a rotating plastic brush.

Scheme 478

Clean sealing surfaces, must be free of oil and grease.

Lubricate the running surfaces of both camshafts.

For new camshafts

Transfer the self-made markings from the old camshafts to the new camshafts.

All

Scheme 479

Install the camshaft with the T40191 as illustrated, move the spacers into the correct position if necessary.

Note. If necessary, use a second set of T40191 or T40191/1.

Install the camshafts into the cylinder head; the factory markings -arrows- must be located as shown in the illustration.

Scheme 480

Note. Ignore the self-made markings.

Check the alignment -arrows- of the camshafts.

Scheme 481

Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Apply the silicone sealant on the clean sealing surface of the cylinder head cover as illustrated -arrows-.

Scheme 482

1. Thickness of sealant bead: 2 to mm.

Note. The cylinder head cover must be installed within 5 minutes after application of silicone sealant. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube. Note the expiration date of the sealing compound.

Sealant

Mount the cylinder head cover on the cylinder head.

Replace the cylinder head cover bolts.

Tighten the bolts in several steps, tightening sequence. (Scheme 386)

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

Drive the cap -1- in without sealing using the T10174.

Scheme 483

a-: 1 to 2 mm

Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Turn the intake camshaft in the direction of the -arrow 1- until the markings -3- align with the T40271/2.

Slide the T40271/2 into the chain sprocket splines in the direction of the -arrow 2-.

Turn the exhaust camshaft in the direction of the -arrow 1- until the markings -3- align with the T40271/1.

Slide the T40271/1 into the chain sprocket splines in the direction of the -arrow 2-.

Position the markings on the chain links -arrows- at the chain sprockets -1- to install the camshaft timing chain.

Install the upper glide track -2-.

Turn the exhaust camshaft in the direction of the -arrow 1-, slide out the T40271/1 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Remove the T40271/1.

Move the tensioning rail -2- up and install the bolt -1-.

Turn the intake camshaft in the direction of the -arrow 1-, slide out the T40271/2 from the chain sprocket splines in the direction of the -arrow 2- and release the camshaft.

Remove the T40271/2.

Check the valve timing. The camshaft timing chain and cylinder head -arrows- must align with the markings on the chain sprocket -1-.

The markings for the camshaft timing chain and the camshaft timing chain glide track -2- must be opposite one another.

The notch on the vibration damper must be opposite the marking on the lower section of the timing chain guard -3-.

Mount the bearing bracket and the bolts -arrows- hand-tight.

Remove the T40011 or the T40267, depending on the version.

Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

Install the bolt -arrow-.

Install the control valve -item 6- in (Scheme 373).

Install the T40196 as illustrated.

Turn the crankshaft 4 complete turns in the direction of engine rotation.

Remove the T40196.

Install the timing chain guard upper section. Refer to UPPER TIMING CHAIN GUARD .

Install the vacuum pump. Refer to Removal and Installation .

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

Install the service position. Refer to Description and Operation .

Install the air filter housing. Refer to Removal and Installation .

Assemble in reverse order of disassembly.

VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Adapter T40012
5. Torque Wrench 5-50 Nm V.A.G 1331
6. Valve Cotters Asm/Dis-Asm Device VAS 5161
7. Guide Plate for FSI Engine VAS 5161/19B

Valve Stem Seals, Removing

Remove the camshafts. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Remove the spark plugs using a 3122 B.

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

Scheme 484

Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

Install the T40012 in the spark plug threads.

Scheme 485

Connect compressed air with at least 6 bar pressure.

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

Intake Side

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

Scheme 486

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

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

Exhaust Side

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

Scheme 487

Press the installation cartridge VAS 5161/8 down while rotating its knurled bolt to the right until the points engage in the valve retainers.

Move the knurled wheel back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

Release the pressure fork VAS 5161/2.

Remove the installation cartridge VAS 5161/8.

Remove the valve stem seals using 3364.

Scheme 488

If the 3364 cannot be used because there is not enough space, drive the roll pin -arrow- out using a drift and remove the impact attachment.

Scheme 489

Position the lower part of the 3364 on the valve stem seal.

Scheme 490

Place the drift -1- in the hole in the lower section of the removal tool.

Position the lever on the removal tool and remove the valve stem seal -arrow-.

Valve Stem Seals, Installing

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

Scheme 491

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

Remove the plastic sleeve -A-.

Insert the valve spring and valve spring plate.

Connect the VAS 5161 as illustrated.

Intake Side

Exhaust Side

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

Press the VAS 5161/8 down with the pressure fork VAS 5161/2 and rotate the cartridge knurled bolt back and forth while pulling up.

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

Remove the VAS 5161.

Further assembly is performed in the reverse order of removal, thereby observing the following

Install the camshafts, refer to CAMSHAFTS .

VALVE STEM SEALS WITH CYLINDER HEAD REMOVED

Special tools and workshop equipment required

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

Procedure

Remove the camshafts. Refer to CAMSHAFTS .

Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

Mount the VAS 6419 into the VAS 6095.

Tension the cylinder head on the cylinder head tensioning device, as illustrated.

Connect the cylinder head tensioning device to the compressed air.

Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seal that will be removed.

Scheme 492

Let enough compressed air flow into the air cushion until it contacts the valve plate.

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

Insert the drift VAS 5161/3 in the guide plate and loosen the stuck valve retainers with a plastic mallet.

Intake Side

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

Insert the installation cartridge VAS 5161/8 in the guide plate for FSI engine VAS 5161/19B.

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

Exhaust Side

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

Press the installation cartridge VAS 5161/8 down while rotating its knurled bolt to the right until the points engage in the valve retainers.

Move the knurled wheel back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

Release the pressure fork VAS 5161/2.

Remove the installation cartridge VAS 5161/8.

Remove valve stem seals using the 3364.

Valve Stem Seals, Installing

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve.

Insert the valve spring and valve spring plate.

Install the VAS 5161 as illustrated.

Intake Side

Exhaust Side

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

Press the VAS 5161/8 down with the pressure fork VAS 5161/2 and rotate the cartridge knurled bolt back and forth while pulling up.

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

Remove the VAS 5161.

Assemble in reverse order of disassembly. When doing this note the following

Install the camshafts, refer to CAMSHAFTS .

Scheme 493

Special tools and workshop equipment required

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

Scheme 494

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Valve Seal Removal Tool 3364
3. Valve Stem Seal Driver 3365
4. Adapter T40012
5. Torque Wrench 5-50 Nm V.A.G 1331
6. Valve Cotters Asm/Dis-Asm Device VAS 5161
7. Guide Plate for FSI Engine VAS 5161/19B

Special tools and workshop equipment required

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

1. Polydrive Bit and Drive Socket T10070
2. Ignition Coil Puller T40039
3. Compression Tester V.A.G 1763
4. Dial Gauge Holder VW 387
5. Dial Gauge 0-10 mm VAS 6079
6. Locking Tool T40098
7. Counter Hold Tool T10355
8. Thrust Piece T10368
9. Thrust Piece T10354
10. Pulling Hook T20143
11. Assembly Tool T10352 and Assembly Tool T10352/1
12. Locking Pin T40011
13. Puller T10394
14. Puller T10055
15. Drift T40196
16. Engine Bung Set VAS 6122
17. Thrust Piece T10174
18. Spacers T40191
19. Not illustrated
20. Polydrive Bit and Drive Socket T10070
21. Pry Lever T40243
22. Camshaft Locator T40271
23. Pulling Hook T40274

See also:
• Removal and Installation
• Description and Operation
• Description and Operation
• MAINTENANCE PROCEDURES
• Removal and Installation
• Removal and Installation
• Description and Operation
• VIBRATION DAMPER
• RIBBED BELT TENSIONING DAMPER
• RIBBED BELT
• RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW
• COOLANT PUMP TOOTHED BELT
• COOLANT PUMP DRIVE SEAL, REPLACING
• COOLANT, DRAINING AND FILLING
• CLEAN WORKING CONDITIONS
• Removal and Installation
• Camshaft Adjustment Valve 1 -N205
• LOWER TIMING CHAIN COVER
• VIBRATION DAMPER SHAFT SEAL
• EXHAUST CAMSHAFT BALANCE SHAFT
• INTAKE CAMSHAFT BALANCE SHAFT
• BALANCE SHAFT TIMING CHAIN
• CYLINDER HEAD WITH WRENCH CLEARANCE
• CYLINDER HEAD WITHOUT WRENCH CLEARANCE
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED
• CAMSHAFTS
• CAMSHAFT TIMING CHAIN OVERVIEW
• CYLINDER HEAD OVERVIEW, WITH WRENCH CLEARANCE
• UPPER TIMING CHAIN GUARD
• CAMSHAFT TIMING CHAIN (WITH NEW TOOLS)
• VALVETRAIN OVERVIEW