VALVETRAIN OVERVIEW Audi TT 8J

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 75

1. Bolt Replace 50 Nm plus an additional 180° turn Use retainer 3036 for loosening and tightening (Scheme 65)
2. Camshaft Sprocket
3. Seal Removing and installing, refer to «EXHAUST CAMSHAFT SEAL»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__exhaust-camshaft-seal)
4. Cylinder Head Reworking dimension (Scheme 76)
5. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valve-guides-checking)
6. Valve Stem Seal
7. Valve Spring
8. Top Valve Spring Retainer
9. Valve Retainers
10. Hydraulic Valve Play Balancing Element Do not interchange Lubricate contact surface
11. Fitted Key Make sure it is secure
12. Exhaust Camshaft Checking axial play, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__camshafts-checking-axial-clearance) 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. Guide Frame With integrated camshaft bearings Clean sealing surface, reworking is not permitted. Remove old sealant residue.
14. Bolt Replace Tightening sequence (Scheme 77)
15. Camshaft Adjuster
16. Bolt Replace 20 Nm plus an additional 45° turn
17. Intake Camshaft Checking axial play, refer to «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__camshafts-checking-axial-clearance) 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. Chain Tensioner Removing camshaft timing adjusters, refer to «CAMSHAFT ADJUSTER»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__camshaft-adjuster) Before removing, secure with locking pin T10115
19. Drive Chain
20. Bolt 10 Nm
21. Bolt 10 Nm
22. Phase Sensor
23. Exhaust Valve Do not reface, only lapping is permitted For the correct valve dimensions (Scheme 78)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valve-guides-checking)
24. Intake Valve Do not reface, only lapping is permitted For the correct valve dimensions (Scheme 78)Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valve-guides-checking)
25. Sealing 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 76

Resurfacing cylinder head (face grinding) is only permissible to minimum dimension -a-.

1. Minimum dimension: a = 139.20 mm

Scheme 77

Replace bolts

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

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

Give 90° ( 1 / 4 turn) additional turn in sequence -1 through 6- using rigid wrench.

Note. Ensure guide frame is not tilted.

Scheme 78

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