2.0l - Cylinder Head, Valvetrain - Engine Code(s): Bpy (coupe) Audi TT 8J

TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover and guard is divided in engine bracket area. Vehicles with divided toothed belt guard - assembly overview, refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.

Scheme 64

1. Bolt 10 Nm Insert with locking fluid Locking fluid.
2. Upper Toothed Belt Guard
3. Bolt Replace 50 Nm plus an additional 180° turn Use retainer 3036 for loosening and tightening (Scheme 65)
4. Camshaft Sprocket When removing and installing, remove toothed belt, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-without-divided-toothed-belt) Installed position is fixed by woodruff key «TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-drive-without-divided-toothed). Camshaft sprocket, removing (Scheme 66)
5. Bolt 10 Nm Insert with locking fluid Locking fluid.
6. Rear Toothed Belt Guard
7. Woodruff Key Make sure it is secure
8. Nut 25 Nm
9. Semi-Automatic Tensioning Roller
10. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-pump)
11. O-ring Replace
12. Bolt 25 Nm
13. Damper Roller
14. Bolt 15 Nm
15. Bolt 35 Nm
16. Damper Roller
17. Sealing Flange Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__front-sealing-flange)
18. Toothed Belt Gear Diamond Disc Replace after removing toothed belt gear
19. Crankshaft Toothed Belt Sprocket There must be no oil on the contact surface between the toothed belt sprocket and crankshaft Only possible to install in one position
20. Bolt Replace 90 Nm plus an additional 90° ( 1 / 4 turn) Do not oil Fastening counter support 3415 (Scheme 67)
21. Toothed Belt Before removing, mark direction of rotation using chalk or felt-tip marker Check for wear Removing, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-without-divided-toothed-belt) Installing (adjusting valve timing), refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-without-divided-toothed-belt)
22. Lower Toothed Belt Guard
23. Engine Support Removing: Toothed belt, removing and installing, refer to «TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-without-divided-toothed-belt) Installing (Scheme 68)
24. Bolt 45 Nm
25. Cover for Toothed Belt Guard

Scheme 65

When loosening and tightening the center bolt, use retainer 3036.

Scheme 66

Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

Scheme 67

When loosening and tightening the center bolt, use retainer 3415.

Scheme 68

Install bolts -1 to 3- hand-tight.

Then tighten bolts, tightening specifications, refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW .

TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover and guard is divided in engine bracket area. Vehicles without divided toothed belt guard - assembly overview, refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW .

Scheme 69

1. Bolt 10 Nm
2. Upper Toothed Belt Guard
3. Bolt 50 Nm plus an additional 180° ( 1 / 2 turn) Use retainer 3036 for loosening and tightening see scheme 7
4. Camshaft Sprocket Installation position secured by woodruff key «TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-drive-with-divided-toothed). Camshaft sprocket, removing see scheme 8
5. Bolt 10 Nm Insert with locking fluid
6. Rear Toothed Belt Guard
7. Woodruff Key Make sure it is secure
8. Bolt 25 Nm
9. Semi-Automatic Tensioning Roller
10. Coolant Pump Removing and Installing, refer to «COOLANT PUMP»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-pump)
11. O-ring Replace
12. Bolt 25 Nm
13. Damper Roller
14. Bolt 15 Nm
15. Bolt 35 Nm
16. Damper Roller
17. Sealing Flange Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__front-sealing-flange)
18. Diamond Disc Replace
19. Crankshaft Toothed Belt Sprocket There must be no oil on the contact surface between toothed belt gear, diamond disc and crankshaft Only possible to install in one position
20. Bolt Replace 90 Nm plus an additional 90° ( 1 / 4 turn) Do not oil Use counter support 3415 for loosening and tightening see scheme 9
21. Toothed Belt Before removing, mark direction of rotation using chalk or felt-tip marker Check for wear Removing and installing, refer to «TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-with-divided-toothed-belt)
22. Lower Toothed Belt Guard
23. Bolts 8 Nm 7 pieces For lower toothed belt guard
24. Engine Support
25. Bolt 45 Nm

When loosening and tightening the center bolt, use retainer 3036.

Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

When loosening and tightening the center bolt, use retainer 3415.

CYLINDER HEAD ASSEMBLY OVERVIEW

Note. Replace the cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. When installing a replacement cylinder head with camshafts installed, contact surfaces between roller rocker lever and cam running surfaces must be oiled. The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

Scheme 70

1. Bolt Tightening sequence (Scheme 71)
2. Cylinder Head Cover Removing and installing, refer to «CYLINDER HEAD COVER»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-cover) Tightening sequence (Scheme 71)
3. Gasket Replace if damaged or leaking
4. Valve Housing
5. Oil Filler Cap
6. Gasket Replace if damaged or leaking
7. Bolt 4 Nm
8. Cylinder Head Cover Gasket Replace if damaged or leaking
9. Vacuum Pump
10. Bolt 4 Nm
11. Camshaft Adjustment Valve 1 -N205- Removing, refer to «CAMSHAFT ADJUSTMENT VALVE 1»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__camshaft-adjustment-valve-1)
12. Seal Replace
13. Bolt 10 Nm
14. Cable Bracket
15. Seal Replace if damaged or leaking
16. Bolt 10 Nm
17. Housing
18. Gasket Replace
19. Transport Strap
20. Bolt 25 Nm
21. Intake Manifold Stud Bolt 10 Nm
22. Partition Plate
23. Cylinder Head Gasket Replace Note installation position: The part number faces the cylinder head Replace coolant after replacing
24. Bolt 10 Nm
25. Camshaft Position Sensor -G40
26. Seal
27. Tensioning Roller Stud Bolt 10 Nm
28. Exhaust Manifold Stud Bolt 20 Nm
29. Cylinder Head Check for distortion (Scheme 74)
30. Cylinder Head Bolt Replace Observe sequence for loosening (Scheme 72)Follow the tightening sequence (Scheme 73)

Scheme 71

Install bolts -1 through 14- and tighten by hand.

Tighten the bolts -1 through 14- diagonally to 10 Nm.

Scheme 72

Loosen cylinder head bolts in sequence shown and remove.

Scheme 73

Tighten cylinder head bolts in -1 through 10- sequence as follows.

1. Tighten to 40 Nm using a torque wrench.

2. Tighten further 90° using a rigid wrench.

3. Tighten further 90° using a rigid wrench.

Scheme 74

Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.

1. Maximum permissible distortion: 0.05 mm.

VALVETRAIN OVERVIEW

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

Scheme 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.

FASTENER TIGHTENING SPECIFICATIONS

Cylinder Head Cover Tightening Sequence

Install bolts -1 to 14- and tighten by hand.

Tighten the bolts -1 to 14- diagonally to 10 Nm.

Loosening the Cylinder Head

Loosen cylinder head bolts in sequence shown and remove.

Cylinder Head Tightening Sequence

Tighten cylinder head bolts in sequence -1 to 10- as follows.

1. Tighten to 40 Nm using a torque wrench.

2. Tighten further 90° using a rigid wrench.

3. Tighten further 90° using a rigid wrench.

Guide Frame Tightening Sequence

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

COMPRESSION, 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

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Scheme 79

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove the ignition coils with power output stage. Refer to Removal and Installation .

Remove spark plugs, using the 3122 B.

Disconnect 8-pin connector from fuel injectors. Refer to Removal and Installation

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

Note. Using tester operating instructions.

Operate starter until tester shows no further pressure increase.

Compression Pressure

Install sparks plugs. Refer to TEST DATA, SPARK PLUGS

Install ignition coils with power output stage. Refer to Removal and Installation .

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

Read out ECM DTC memory. Vehicle diagnostic, testing and information system VAS 5051 in "Guided Fault Finding" function.

CAMSHAFTS, CHECKING AXIAL CLEARANCE

Special tools and workshop equipment required

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

Test Sequence

Perform measurement with guide frame removed.

Place camshaft to be checked in guide frame.

Secure the VAS 6079 to cylinder head with VW 387.

Scheme 80

Press camshaft against dial gauge by hand.

Set dial gauge to "0".

Press camshaft off dial gauge and read the value

1. Axial clearance: 0.05 to 0.17 mm.

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 the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

Scheme 81

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.

TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover and guard is divided in engine bracket area. Toothed belt, vehicles with divided toothed belt guard, removing and installing TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Spindle 10 - 222 A /11; quantity: 2
3. Special Hook 10 - 222 A /20; quantity: 2
4. Additional Hooks (2)10 - 222 A /2
5. Engine Support Basic Set T40091
6. Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3
7. Toothed Belt Tensioner T10020
8. Locking Pin T10060A

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Open cap of coolant expansion tank.

Remove center noise insulation fasteners -1 to 4-.

Scheme 82

Remove the right noise insulation -arrows-.

Scheme 83

Remove noise insulation frame -arrow-.

Scheme 84

Remove the bolts -arrows- and disconnect charge air pipe with hoses.

Scheme 85

Remove the bolts -1 to 3- and the pendulum support.

Scheme 86

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Mark the fuel line -1- and the Evaporative Emission (EVAP) line -2-.

Scheme 87

Disconnect fuel line -1-.

Disconnect the EVAP line -2-.

Disconnect the EVAP line to fuel tank -3-.

Remove EVAP canister upward in direction of -arrow-.

Loosen the coolant hose from the retainer -1-.

Scheme 88

Remove bracket for EVAP filter -arrows-.

Unbolt the filler tube for the windshield washer fluid reservoir -1-.

Scheme 89

Remove the retaining clip, by removing bolts -2 and 3-.

Disconnect the electrical connector -1- from coolant level indicator.

Scheme 90

Remove coolant expansion tank -arrows-.

Disconnect coolant pipe -arrow-.

Scheme 91

Remove the ribbed belt. Refer to RIBBED BELT .

Remove ribbed belt tensioner -arrows-.

Scheme 92

Remove EVAP canister bracket.

Loosen coolant pipe -arrows-.

Scheme 93

Disengage shift cable -arrow-.

Scheme 94

Position the 10 - 222 A on fender bolting edge with the following tool parts

Scheme 95

1. Engine brackets 10 - 222 A /1, quantity: 2
2. Engine support bridge 10 - 222 A
3. Spindle 10 - 222 A /11 (spindle faces forward)
4. Additional hooks 10 - 222 A /2
5. Adapter 10 - 222 A /20
6. Connectors T40091/3 qty. 2

Engage spindle 10 - 222 A /11 with 10 - 222 A /2 and special hook 10 - 222 A /20 on transmission lifting eye.

Tension engine/transmission subframe with spindle.

Install adapter T40093/3-2 (left) and T40093/3-3 (right) on supports T40093/3.

Scheme 96

Remove ground (GND) line from left longitudinal member.

Remove left and right connecting bolt for front section of the long member.

Secure adapter to the long members with bolts -arrow- removed earlier.

Note. The illustration shows the left side of the vehicle.

Scheme 97

Slide support T40091/2 into both connectors T40093/4 with slide T40093/5.

Scheme 98

Install 10 - 222 A /11 with 10 - 222 A /20 on slide and on engine lifting eye.

Tension engine/transmission subframe by evenly tightening the 2 spindles.

Remove bolts from assembly mount/engine support -arrows- remove assembly mount completely.

Scheme 99

Lift the engine with the 10-222A so far that both upper bolts -1 and 2- of the engine support can be loosened and removed.

Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

Scheme 100

Remove vibration damper/belt pulley.

Scheme 101

Remove the bolts from lower section of the toothed belt guard -arrows-.

Scheme 102

Loosen the lower bolts -3- and remove the engine support downward and out.

Remove remaining bolts from toothed belt guard -arrows- and remove toothed belt guard from engine.

Scheme 103

Mark rotational direction of toothed belt.

Loosen tensioning roller and remove toothed belt.

Then, turn the crankshaft back slightly.

Installing

1. For the correct tightening specifications, refer to «TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-drive-without-divided-toothed) .

Note. When turning the camshaft, the crankshaft must not be at TDC. Valves and/or pistons may be damaged. The engine must be no more than warm to touch.

Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

Secure the lower toothed belt guard with the two lower bolts.

Install vibration damper with new bolts.

Set the crankshaft and camshaft to TDC at cylinder 1 -arrows-.

Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley -arrow-.

Scheme 104

Note. Be sure tensioning roller is properly seated in cylinder head.

Tension toothed belt. Do this by turning the hex key at the eccentric toward the right (in direction of -arrow-) until the notch is positioned above the tab.

Scheme 105

Release tension on toothed belt again.

Now tension toothed belt until notch and tab align.

Tighten mounting nut.

Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this it is necessary that the last 45° ( 1 / 8 rotation) is turned without interruption.

Check tension of toothed belt again. Specified value: Tab and notch align.

Check the valve timing again.

If the markings do not match

Repeat valve timing adjustment.

If the markings match

Install the toothed belt guard -arrows-.

Scheme 106

Note. Note different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Insert the lower bolt -3- into the engine support.

Install the engine support from below onto the cylinder block and hand-tighten the bolt.

Lift the engine with the 10-222A so far that both upper bolts -1 and 2- can be screwed in.

Tighten all bolts.

Lower engine to installation position.

Install subframe mount for engine completely.

Fasten engine assembly mount to engine support -arrows-, bringing the contact surfaces into contact using the 10-222A.

Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

Connect fuel hoses to connections. Make sure connector couplings are securely fastened.

Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .

Install coolant expansion tank.

Install noise insulation.

Install the engine cover.

Install vibration damper. Refer to VIBRATION DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD

Note. Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover and guard is divided in engine bracket area. Toothed belt, vehicles without divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Spindle 10 - 222 A /11; quantity: 2
3. Special Hook 10 - 222 A /20; quantity: 2
4. Additional Hooks (2)10 - 222 A /2
5. Engine Support Basic Set T40091
6. Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3
7. Toothed Belt Tensioner T10020
8. Locking Pin T10060A

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Open cap of coolant expansion tank.

Remove center noise insulation fasteners -1 to 4-.

Remove the right noise insulation -arrows-.

Remove noise insulation frame -arrow-.

Remove the bolts -arrows- and disconnect charge air pipe with hoses.

Remove the bolts -1 to 3- and the pendulum support.

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Mark the fuel line -1- and the EVAP line -2-.

Disconnect fuel line -1-.

Disconnect the EVAP line -2-.

Disconnect the EVAP line to fuel tank -3-.

Remove EVAP canister upward in direction of -arrow-.

Loosen the coolant hose from the retainer -1-.

Remove bracket for EVAP filter -arrows-.

Unbolt the filler tube for the windshield washer fluid reservoir -1-.

Remove the retaining clip, by removing bolts -2 and 3-.

Disconnect the electrical connector -1- from coolant level indicator.

Remove coolant expansion tank -arrows-.

Disconnect coolant pipe -arrow-.

Remove the ribbed belt. Refer to RIBBED BELT .

Remove ribbed belt tensioner -arrows-.

Loosen coolant pipe -arrows-.

Remove the bolts -arrows- and the toothed belt guard.

Scheme 107

Disengage shift cable -arrow-.

Position the 10 - 222 A on the fender bolting edge with the following tool parts

1. Engine brackets 10 - 222 A /1, quantity: 2
2. Engine support bridge 10 - 222 A
3. Spindle 10 - 222 A /11 (spindle faces forward
4. Additional hooks 10 - 222 A /2
5. Adapter 10 - 222 A /20
6. Connectors T40091/3 qty. 2

Engage the 10 - 222 A /11 with the 10 - 222 A /2 and 10 - 222 A /20 on the transmission lifting eye.

Tension engine/transmission subframe with spindle.

Install adapters T40093/3-2 (left) and T40093/3-3 (right) on supports T40093/3.

Remove ground (GND) line from left longitudinal member.

Remove left and right connecting bolt for front part of long member.

Secure adapter to long members with bolts removed earlier -arrow-.

Note. The illustration shows the left side of the vehicle.

Place the square pipes T40091/1 with connector T40093/4 in the connector T40091/3 and supports T40093/3-3 as shown in the illustration.

Slide the support T40091/2 into both connectors T40093/4 with slide T40093/5.

Install the 10 - 222 A /11 with 10 - 222 A /20 on slide and on engine lifting eye.

Tension engine/transmission subframe by evenly tightening the 2 spindles.

Remove bolts from assembly mount/engine support -arrows- remove assembly mount completely.

Lift the engine with the 10-222A so far that both upper bolts -1 and 2- of engine support can be loosened and removed.

Bring camshaft gear to marking for TDC cylinder 1 by turning the crankshaft. Marking on the camshaft gear must align with arrow on toothed belt guard.

Scheme 108

Remove vibration damper/belt pulley.

Remove lower bolts from lower section of toothed belt guard -arrows-.

Scheme 109

Identify TDC position -arrow-.

Scheme 110

Remove both upper bolts from toothed belt guard -arrows- and remove guard downward from engine.

Scheme 111

Loosen the lower bolts -3- and remove the engine support downward and out.

Mark rotational direction of toothed belt.

Loosen tensioning roller and remove toothed belt.

Then, turn the crankshaft back slightly.

Installing

1. For the correct tightening specifications, refer to «TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__toothed-belt-drive-without-divided-toothed) .

Note. When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged. The engine must be no more than warm to touch.

Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

Secure the lower toothed belt guard with the two lower bolts.

Install vibration damper with new bolts.

Position camshaft and crankshaft on TDC marking.

Scheme 112

Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley -arrow-.

Note. Be sure tensioning roller is properly seated in cylinder head.

Tension toothed belt. Do this by turning the hex key at the eccentric toward the right (in direction of -arrow-) until the notch is positioned above the tab.

Release tension on toothed belt again.

Now tension toothed belt until notch and tab align.

Tighten mounting nut.

Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this, it is necessary that the last 45° ( 1 / 8 rotation) is turned without interruption.

Check tension of toothed belt again. Specified value: Tab and notch align.

Check valve timing. The markings must align -arrows-.

If the markings do not match

Repeat valve timing adjustment.

If the markings match

Bring engine bracket into installation position.

Install toothed belt guard from below -arrows-.

Install vibration damper/belt pulley with new bolts.

Check the valve timing again: The markings must align -arrows-.

Tighten both toothed belt guard upper bolts -arrows-.

Note. Note different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Insert the lower bolt -3- into the engine support.

Install the engine support from below onto the cylinder block and hand-tighten the bolt.

Lift the engine with the 10-222A so far that both upper bolts -1 and 2- can be screwed in.

Tighten all bolts.

Lower engine to installation position.

Install subframe mount for engine completely.

Fasten engine assembly mount to engine support -arrows-, bringing the contact surfaces into contact using the 10-222A.

Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

Connect fuel hoses to connections. Make sure connector couplings are securely fastened.

Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .

Install coolant expansion tank.

Install noise insulation.

Install the engine cover.

Install vibration damper. Refer to VIBRATION DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

CAMSHAFT ADJUSTMENT VALVE 1

Special tools and workshop equipment required

1. Torque Wrench 5-60 Nm V.A.G 1783
2. TORX® Bit Set V.A.G 1766
3. Ratchet Insert 1/4" VAS 6234
4. Hose Type Clip Pliers VAS 5024 A

Removing

Note. Always replace gaskets and seals.

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Separate electrical connector -1-.

Scheme 113

Disengage wiring harness -2- from bracket.

Remove the bolt -3-.

Note. Do not pull out the camshaft adjustment valve 1 -N205- at connector.

Remove bolts -arrows- and remove camshaft adjustment valve 1 from housing.

Scheme 114

Installing

1. Tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-assembly-overview)

Note. Camshaft adjustment valve 1 as well as housing must be free of dirt and contamination. Remove the new camshaft adjustment valve 1 from packaging only prior to installation.

Coat sealing ring with engine oil.

Carefully insert camshaft adjustment valve 1 into housing and press it in perpendicular to valve axle by hand as far as stop.

Install bolts and tighten to 4 Nm with the V.A.G 1783, VAS 6234, TORX-Bit T20 and bit holder from V.A.G 1766.

Assemble in reverse order of disassembly.

CYLINDER HEAD COVER

Removing

Special tools and workshop equipment required

1. Ignition Coil Puller T40039
2. Hose Clip Pliers V.A.G 1921

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from the MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove air guide hose -arrow- with the V.A.G 1921.

Scheme 115

Remove the bolts -arrows-.

Remove the ignition coils with power output stage. Refer to Removal and Installation .

Disconnect the Evaporative Emission (EVAP) line from the cylinder head cover -1-.

Scheme 116

Remove valve housing from cylinder head cover -arrows-.

Remove the crankcase ventilation line and heat shield from the turbocharger -1-.

Scheme 117

Disconnect the EVAP line to the turbocharger from the cylinder head cover -2-.

Loosen the cylinder head cover starting from the outside and working toward the inside.

Remove the cylinder head cover.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-assembly-overview)

Note. Replace the cylinder head cover gaskets if they are damaged. Observe tightening sequence for cylinder head cover (Scheme 71)

Make sure the upper toothed belt guard is installed correctly.

Install ignition coils with power output stage. Refer to Removal and Installation .

Special tools and workshop equipment required

1. Drip Tray VAS 6208
2. Retainer 3036
3. Puller T40001
4. Ignition Coil Puller T40039
5. Hose Clip Pliers V.A.G 1921
6. Engine Support Bridge 10 - 222 A
7. Shackle 10 - 222 A /12
8. Locking Pin T10060A
9. Tooth Belt Tensioner T10020
10. Polydrive Bit and Drive Socket T10070
11. Engine Bung Set VAS 6122

Removing

1. Engine installed.

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Perform oil change if engine oil is contaminated. Refer to Maintenance Procedures. If using sealant, note current specifications.

Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove air guide hose -arrow- with the V.A.G 1921.

Open cap of coolant expansion tank.

Remove center noise insulation fasteners -1 to 4-.

Remove the right noise insulation -arrows-.

Remove noise insulation frame -arrow-.

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.

Scheme 118

Disconnect the coolant line to coolant expansion tank -arrow-.

Scheme 119

Disconnect coolant hose -1-.

Scheme 120

Disconnect coolant hose -2-.

Remove Ground (GND) wire nut -1-.

Scheme 121

Separate electrical connector -2-.

Disconnect coolant hoses -arrows-.

Remove the intake manifold. Refer to Removal and Installation .

Remove the right drive axle heat shield -arrows-.

Scheme 122

Remove nuts -1- and -2- on oxygen sensor electrical connector bracket under vehicle floor and remove cover.

Scheme 123

Remove bolt -3- and free up electrical wiring to oxygen sensor.

Remove connector coupling from bracket -arrow-.

Scheme 124

Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) -G130-.

Remove the remaining nuts -arrows- for the front exhaust pipe/turbocharger from below.

Scheme 125

Remove exhaust system bracket and tunnel brace -arrows-.

Scheme 126

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.

Disconnect the exhaust system at the clamping sleeve -arrows-.

Scheme 127

Remove front exhaust pipe with catalytic converter and front muffler.

Remove right drive axle. Refer to Removal and Installation .

Disconnect air guide pipe -arrow- from charge air cooler.

Scheme 128

Unfasten air duct from turbocharger -arrows-.

Scheme 129

Disconnect the connector -1 and 2- and free up the cable.

Remove bolts -arrows- and remove air guide pipe.

Note. The illustration depicts the engine removed from behind.

Unfasten turbocharger oil supply line at cylinder block -1-.

Scheme 130

Remove turbocharger oil supply line -2-.

Unfasten turbocharger coolant supply line at cylinder block -1-.

Scheme 131

Remove coolant supply line to turbocharger -2-.

Remove the coolant supply line for turbocharger -3- at the cylinder block.

Disconnect oil return line -arrows- on turbocharger.

Scheme 132

Remove bolts -1- and -2- and remove support for turbocharger.

Scheme 133

Remove the toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Loosen the bolt for camshaft sprocket using the 3036.

Pull off the camshaft sprocket using the T40001 and claws T40001/6 and T40001/7.

Remove rear toothed belt guard from cylinder head -arrows-.

Scheme 134

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Loosen the cylinder head bolts using a T10070, paying attention to the sequence of the cylinder head bolts.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected.

Remove cylinder head.

Cylinder Head, Installing

1. Tightening specifications and tightening sequence, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-assembly-overview)
2. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-overview)

Note. Replace the cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. Secure all hose connections using hose clamps appropriate for the model type. Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Hot bolt paste.

Note. Turning over the engine is performed at the center bolt of the crankshaft.

Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts -arrows- now face toward each other vertically.

Scheme 135

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

Set cylinder head gasket in place.

Scheme 136

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

Set cylinder head in place.

Insert cylinder head bolts and tighten by hand.

Cylinder head, tightening sequence. (Scheme 73)

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

Install cylinder head cover. Refer to CYLINDER HEAD .

Install wiper arm. Refer to [For transmission(s) 02E] Removal and Installation .

Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Install the ribbed belt. Refer to RIBBED BELT .

Electrical connections and routing.

Install the intake manifold. Refer to Removal and Installation .

Air guide pipes with connector, installing. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .

Connect battery. Refer to [For transmission(s) 02E] Removal and Installation .

Install fuel system. Refer to Removal and Installation .

Check oil level. Refer to Maintenance Procedures.

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant may not be used again.

CAMSHAFT ADJUSTER

Special tools and workshop equipment required

1. Socket T40080
2. Camshaft Clamp T10252
3. Toothed Belt Tensioner T10020
4. Locking Pin T10115

Removing

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

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove vacuum pump.

Remove camshaft adjuster housing -arrows-.

Scheme 137

Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts -arrows- now face toward each other vertically.

Install the T10252 as shown and secure -arrows-.

Scheme 138

Loosen mounting bolt from camshaft adjuster using the T40080.

Compress chain tensioner -arrow A- and secure it using the T10115 -arrow B-.

Scheme 139

Remove the bolt from the camshaft adjuster and then remove the adjuster and the chain.

Installing

1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valvetrain-overview)
2. For the correct tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-assembly-overview)

1. The camshafts must be fixed in place with the T10252.

Place the chain on to camshaft adjuster.

Hold the camshaft adjuster in front of the exhaust camshaft so that the notch -A- and pin -B- are positioned across from one another.

Scheme 140

Place chain in this position on to chain sprocket of the intake camshaft, first at top -arrow-.

Scheme 141

Slowly turn the intake camshaft with the T10020 in direction of -arrow A- until the camshaft adjuster fits onto the camshaft.

Scheme 142

Note. If pin does not fit into notch: Remove chain and place the chain on again.

Replace camshaft adjuster mounting bolt.

Tighten camshaft adjuster screw. To do so, use the T40080.

Remove the T10115 -arrow B-.

Assemble in reverse order of disassembly.

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Install high pressure pump. Refer to Removal and Installation .

Install vacuum pump. Refer to Removal and Installation .

CAMSHAFTS

Special tools and workshop equipment required

1. Puller T40001
2. Retainer 3036

Removing

Note. Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked. Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, tension on toothed belt must be released. If guide frame was loosened, camshaft sealing ring and sealing cap must be replaced.

Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Remove toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Loosen camshaft gear with the 3036.

Scheme 143

Pull off camshaft gear using the T40001, T40001/6 and T40001/7.

Remove toothed belt guard at rear of cylinder head.

Remove guide frame bolts in sequence -6 through 1- and carefully remove guide frame.

Remove camshafts together with drive chain from cylinder head.

Installing

1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valvetrain-overview)
2. For the correct tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__cylinder-head-assembly-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 the old sealant from the guide frame groove and from sealing surfaces.

Scheme 144

Prevent dirt and adhesive residue from entering cylinder head.

Oil journal surfaces of camshafts.

Place the drive chain onto the removed camshaft chain sprockets as follows

Oil journal surfaces of camshafts.

Scheme 145

1. Cams -A- of cylinder 4 must face each other.
2. The notches -arrows- on both camshafts must align.
3. The side surfaces of the notches must be exactly vertical.

Place camshafts together with drive chain in cylinder head and in chain tensioner.

Verify TDC position of camshafts again.

Scheme 146

1. Cams -A- of cylinder 4 must face each other.
2. The notches -arrows- on both camshafts must align.
3. The side surfaces of the notches must be exactly perpendicular to the cylinder head.

Oil journal surfaces of camshafts.

Apply an even, light sealant bead into the clean groove of the guide frame.

Sealant

Note. Sealant must not be applied too thickly. Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces. Note the expiration date of the sealing compound.

Set the guide frame in place so that it can get by the EGR vacuum regulator solenoid valve -N18- -arrow-.

Scheme 147

Replace guide frame bolts.

Note. The placement of the camshafts must be exact within the axial bearings of the guide frame.

Tighten bolts in several stages in tightening sequence. (Scheme 77)

Note. Ensure guide frame is not tilted.

Then check TDC position of camshafts by inserting the -T10252- as far as stop.

Note. Rotate camshafts back and forth slightly if necessary to insert the -T10252-. Ignore -arrows-.

If the -T10252- cannot be inserted, remove guide frame again and repeat camshaft installation VALVE STEM SEALS WITH CYLINDER HEAD REMOVED .

Remove the -T10252-.

Drive in the sealing cap VALVETRAIN OVERVIEW with the thrust piece 3334 approximately 1 to 2 mm deep.

Install camshaft sealing ring. Refer to EXHAUST CAMSHAFT SEAL .

Install the rear toothed belt guard.

Insert fitting key into camshaft.

Install the camshaft sprocket. Hold the camshaft sprocket with the 3036 and tighten the bolt

Note. When turning camshaft, pistons may not be at TDC for any cylinder. Valves/pistons may be damaged. Be sure fitting keys are properly seated.

Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Install camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Assemble in reverse order of disassembly.

VALVE STEM SEALS, 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 VAS5161
7. Guide Plate for FSI Engine VAS 5161/19B

Valve Stem Seals, Removing

Remove the camshafts. Refer to CAMSHAFTS .

Note. To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR vacuum regulator solenoid valve -N18- must also be removed.

Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.

Remove the spark plugs with the 3122 B.

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

Scheme 148

Adjust piston of the respective cylinder to "Bottom Dead Center (BDC)".

Install the T40012 into the spark plug thread and connect compressed air (minimum 6 bar).

Scheme 149

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

For the 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 150

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.

For the 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 151

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.

Scheme 152

In the event the 3364 cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve -arrow- using a drift and remove impact device.

Scheme 153

Place the lower part of the 3364 onto the valve stem seal.

Scheme 154

Insert a drift -1- into the bore in lower part of extractor device.

Place a lever at the removal tool and pull out the valve stem seal -arrow-.

Valve Stem Seals, Installing

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

Scheme 155

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

Remove the plastic sleeve -A-.

Insert valve spring and valve spring retainer.

Install the VAS 5161 as shown.

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

Press down the VAS 5161/8 with the pressure fork VAS 5161/2 and turn the knurled screw of the installation cartridge back and forth while pulling it upward at the same time.

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

Remove the VAS 5161.

Assemble in reverse order of disassembly.

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.

Scheme 156

Tension the cylinder head on the VAS 6419 as illustrated.

Connect the VAS 6419 to the compressed air.

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

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

Place the guide plateVAS 5161/19B from the VAS 5161 on the cylinder head.

Secure the guide plate with the knurled screws VAS 5161/12.

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

Scheme 157

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 158

Slide installation cartridge VAS 5161/8 in guide plate.

Intake Side

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

Exhaust Side

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

Scheme 159

Continued for Both Sides

Press the installation cartridge down with the pressure fork.

At the same time, rotate installation cartridge knurled screw right until points engage in valve retainers.

Move the knurled bolt to the left and right.

1. Valve retainer are pressed against each other and capture in the installation cartridge.

Release the pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

Remove the valve spring and the valve spring plate.

Remove the valve stem seal with the 3364.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with the 3365.

Remove plastic sleeve again.

When the valve retainers were removed from the installation cartridge, they must be inserted in the valve retainer inserting tool VAS 5161/18 next.

Scheme 160

1. The large diameter of the valve retainers point upward.

Press installation cartridge from above onto valve retainer inserting tool and capture retainers.

Insert valve spring and valve spring plate.

Install the guide plate on the cylinder head.

Insert installation cartridge with knurled spacer ring in guide plate.

Press pressure fork down and pull knurled screw up, turning left and right.

1. The valve keepers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Repeat the procedure on each valve.

Assemble in reverse order of disassembling. Note the following

Install the camshafts. Refer to CAMSHAFTS .

EXHAUST CAMSHAFT SEAL

Special tools and workshop equipment required

1. Seal Puller - General Useage 2085
2. Retainer 3036
3. Assembly Tool T10071
4. Puller T40001
5. Toothed Belt Tensioner T10020
6. Locking Pin T10060A

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Open cap of coolant expansion tank.

Remove center noise insulation fasteners -1 to 4-.

Remove the right noise insulation -arrows-.

Remove noise insulation frame -arrow-.

Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Loosen camshaft sprocket, using the 3036.

Pull off the camshaft sprocket using the T40001 and claws T40001/6 and T40001/7.

To guide seal puller, thread special tool 2085/2 of the 2085 into the camshaft by hand up to the stop.

Scheme 161

Unscrew inner portion of 2085 two rotations (approximately 3 mm) from outer portion and secure with knurled-head bolt.

Lubricate threaded head of 2085, position and forcefully screw into seal as far as possible.

Scheme 162

Loosen knurled bolt and turn inner part against camshaft until seal is removed.

Secure the seal remover in a vise at the flat spots. Remove seal using pliers

Installing

1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-bpy-coupe__valvetrain-overview)

Do not seal lip of sealing ring.

Place the guide sleeve T10071/1 from the T10071 on camshaft pin.

Scheme 163

Slide seal over guide sleeve onto shaft pin.

Remove the guide sleeve.

Press sealing ring on as far as stop with the guide sleeve T10071/3 and screw T10071/4 from the T10071.

Scheme 164

Scheme 165

1. Note installation position: Thin rib on the camshaft gear points outward -arrows- and the TDC marking on cylinder 1 is visible.

Install the bolt for camshaft sprocket using the 3036.

Note. By turning the camshaft, the valves could contact the stationary pistons at TDC. Therefore, the pistons must not be at TDC. Valves/pistons may be damaged.

Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Scheme 166

Special tools and workshop equipment required

1. Drip Tray VAS 6208
2. Retainer 3036
3. Puller T40001
4. Ignition Coil Puller T40039
5. Hose Clip Pliers V.A.G 1921

Scheme 167

Special tools and workshop equipment required

1. Socket T40080
2. Camshaft Clamp T10252
3. Toothed Belt Tensioner T10020
4. Locking Pin T10115

Scheme 168

Special tools and workshop equipment required

1. Torque Wrench 5-60 Nm V.A.G 1783
2. TORX® Bit Set V.A.G 1766
3. Ratchet Insert 1/4" VAS 6234
4. Hose Type Clip Pliers VAS 5024 A

Scheme 169

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Shackle 10 - 222 A /12
3. Locking Pin T10060A
4. Tooth Belt Tensioner T10020
5. Polydrive Bit and Drive Socket T10070

Scheme 170

Special tools and workshop equipment required

1. Seal Puller - General Useage 2085
2. Retainer 3036
3. Assembly Tool T10071
4. Puller T40001

Scheme 171

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Spindle 10 - 222 A /11; quantity: 2
3. Special Hook 10 - 222 A /20; quantity: 2
4. Additional Hooks (2)10 - 222 A /2
5. Engine Support Basic Set T40091
6. Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3

Scheme 172

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 173

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 174

Scheme 175

Scheme 176

Scheme 177

1. Compression Tester V.A.G 1763
2. Dial Gauge Holder VW 387
3. Dial Gauge 0-10 mm VAS 6079
4. Engine Bung Set VAS 6122

See also:
• COOLANT PUMP
• FRONT SEALING FLANGE
• Removal and Installation
• Removal and Installation
• TEST DATA, SPARK PLUGS
• COOLING SYSTEM, DRAINING AND FILLING
• RIBBED BELT
• SUBFRAME MOUNT, ADJUSTING
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING
• VIBRATION DAMPER
• Removal and Installation
• EXHAUST SYSTEM OVERVIEW
• [For transmission(s) 02E] Removal and Installation
• [For transmission(s) 02E] Removal and Installation
• Removal and Installation
• TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD
• TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD
• TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW
• TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW
• CYLINDER HEAD COVER
• CAMSHAFT ADJUSTMENT VALVE 1
• EXHAUST CAMSHAFT SEAL
• VALVE GUIDES, CHECKING
• CAMSHAFTS, CHECKING AXIAL CLEARANCE
• CAMSHAFT ADJUSTER
• CYLINDER HEAD ASSEMBLY OVERVIEW
• CYLINDER HEAD
• VALVETRAIN OVERVIEW
• VALVE STEM SEALS WITH CYLINDER HEAD REMOVED
• CAMSHAFTS