3.2l - Cylinder Head, Valvetrain - Engine Code(s): Cbra (roadster) Audi TT 8J

Scheme 795

1. Cylinder Head Gasket Replace After replacing, change engine oil and coolant
2. Cylinder Head Removal and installation, refer to «CYLINDER HEAD»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster) Check for distortion (Scheme 799)After replacing, change engine oil and coolant
3. Lifting Eye
4. Bolt 23 Nm
5. Cylinder Head Cover Gaskets Replace if damaged
6. Cylinder Head Cover Removal and installation, refer to «CYLINDER HEAD COVER»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__cylinder-head-cover)
7. Spacing Sleeve With seal Replace seal if damaged
8. Nut 10 Nm
9. Cap
10. Seal for Filler Cap Replace if damaged
11. Rubber Buffer Replace if damaged
12. Ignition Coil Use puller for ignition coil T10095 A for removal
13. Bolt With spacer sleeve and seal Replace seal if damaged Tightening specifications and tightening sequence (Scheme 796)
14. Bolt 10 Nm
15. Bolt 10 Nm
16. Bracket For fuel line
17. Bolt Replace Observe sequence for loosening (Scheme 797)Tightening specifications and tightening sequence (Scheme 798)
18. Lifting Eye
19. Bolt 23 Nm
20. Bolt
21. Secondary Air Injection (AIR) Combination Valve Version and installation location, refer to «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cbra-roadster-as-of-032009__secondary-air-injection-system-assembly-overview)

Scheme 796

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

Scheme 797

Loosen the bolts in sequence -1 to 20-.

Scheme 798

Tighten bolts in 4 stages in -1 to 20- sequence as follows

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten bolts by hand.

Tighten the bolts to 30 Nm.

Tighten the bolts to 50 Nm.

Tighten an additional 180° ( 1 / 2 turn).

Scheme 799

Measure at several places with straight edge and feeler gauge.

Permissible distortion

1. Maximum 0.05 mm.

TIMING CHAIN COVERS ASSEMBLY OVERVIEW

Note. Items -1 through 3-, refer to DUAL-MASS FLYWHEEL COMPONENT OVERVIEW .

Scheme 800

1. 4 - Bolt Tightening specifications (Scheme 801)
2. 5 - Thermostat Housing Removal and installation, refer to «COOLANT THERMOSTAT HOUSING»(/audi/tt/8j-2006-2010/remont/cooling-fan/#32l-cooling-system-engine-codes-cbra-roadster__coolant-thermostat-housing)
3. 6 - Bolt 10 Nm
4. 7 - Bracket Illustration does not correspond to version in vehicle
5. 8 - Gasket Replace
6. 9 - Seal 2 pieces For Camshaft Adjustment Valve 1 -N205- and Camshaft Adjustment Valve 1 (exhaust) -N318- Replace if leaking or damaged Replacing, refer to «TIMING CHAIN UPPER COVER SEAL»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-chain-upper-cover-seal).
7. 10 - Bolt 10 Nm
8. 11 - Camshaft Position Sensor 2 pieces Mark the electrical connector before disconnecting
9. 12 - O-ring 2 pieces Replace
10. 13 - Upper Timing Chain Cover Coat sealing surfaces with sealant when installing «LIGHTLY COAT CLEAN SEALING SURFACE -SHADED- ON TIMING CHAIN UPPER COVER WITH SEALANT»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__lightly-coat-clean-sealing-surface-shaded)
11. 14 - Alignment Bushing 2 pieces
12. 15 - Gasket Replace
13. 16 - O-ring Replace
14. 17 - Seal Replace if leaking or damaged
15. 18 - Camshaft Timing Chain Tensioner Tightening specifications, refer to «TIMING CHAIN COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster)
16. 19 - Bolt Tightening specifications and tightening sequence (Scheme 801)
17. 20 - Cylinder Head Gasket Clean holes and fill with sealant «CLEAN SEALANT RESIDUE FROM 3 MM BORES -ARROWS- IN CYLINDER HEAD SEAL»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster)
18. 21 - Fitting Pin
19. 22 - Lower Timing Chain Cover When installing, coat the sealing surfaces with sealant; sealant.
20. 23 - Bolt 10 Nm Fasten in diagonal sequence in steps

Scheme 801

1. Pre-tighten the bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tighten the bolts -1- and -2- to 10 Nm.

Scheme 802

1. Control Housing Removal and installation, refer to «CAMSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshafts) Disassembling and assembling (Scheme 810)Check screen for dirt (Scheme 811)Lightly lubricate contact surfaces of oil seals before installing
2. Bolt Replace 8 Nm
3. Camshaft Timing Chain Before removing, mark direction of rotation with paint (Scheme 803)Remove from camshafts, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain) Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-mechanism-drive-chain-and-camshaft)
4. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain)
5. Intermediate Shaft
6. Thrust Washer
7. Bolt Insert with locking compound; Locking compound. 8 Nm
8. Timing Chain Tensioning Rail Remove to remove and install timing chain upper and lower covers
9. Mounting Pin
10. Camshaft Timing Chain Tensioner Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain) 40 Nm
11. Seal Replace if leaking or damaged
12. Timing Mechanism Drive Chain Sprocket Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-mechanism-drive-chain-and-camshaft)
13. Camshaft Timing Chain Sprocket Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-mechanism-drive-chain-and-camshaft)
14. Bolt Use Counterhold T10069 on vibration damper to loosen and tighten Replace 60 Nm plus an additional 90° ( 1 / 4 ) turn.
15. Chain Tensioner with Tensioning Rail For drive chain Before installation release the locking device in the chain tensioner with a small screwdriver and press the tensioning plate against the chain tensioner
16. Drive Sprocket Integral part of crankshaft
17. Power Take-Off Drive Chain Before removing, mark direction of rotation with paint (Scheme 803)Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-mechanism-drive-chain-and-camshaft)
18. Timing Mechanism Drive Chain Guide Rail Removal and installation, refer to «TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-mechanism-drive-chain-and-camshaft)
19. Pin For guide rail 10 Nm
20. Mounting Pin 18 Nm
21. Bolt 23 Nm
22. Camshaft Adjuster, Intake Side Identification: "24E" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain)
23. Bolt To loosen and tightening, counterhold with open-end spanner on camshaft hex head, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain) Replace Contact surface of sensor wheel at screw head must be dry when installing 60 Nm plus an additional 90° ( 1 / 4 ) turn.
24. Camshaft Timing Chain Guide Rail Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain)
25. Camshaft Adjustment Valve 1 -N205- For intake camshaft Mark the electrical connector before disconnecting
26. Camshaft Adjustment Valve 1 (exhaust) -N318- For exhaust camshaft Mark the electrical connector before disconnecting
27. Camshaft Timing Chain Guide Rail Clipped in at control housing

Scheme 803

Mark timing chain running direction with arrows using paint -arrows- for reinstallation.

Scheme 804

A- Flywheel-side view

B- Vibration damper-side view

Notches -arrows- are reference points for markings on camshaft adjusters.

VALVETRAIN COMPONENT OVERVIEW

Scheme 805

1. Camshaft Adjuster, Exhaust Side Identification: "32A" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain)
2. Bolt For removal and installation, counter-hold at camshaft hex head with open-end spanner, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain) Replace Tightening specifications -23- «TIMING CHAIN COMPONENT OVERVIEW Bolt»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster)
3. Camshaft Adjuster, Intake Side Identification: "24E" Removal and installation, refer to «CAMSHAFT TIMING CHAIN»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-timing-chain)
4. Control Housing Removal and installation, refer to «CAMSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshafts) Check control housing strainer for contamination before installation (Scheme 811) Lightly lubricate contact surfaces of oil seals before installing Disassembling and assembling (Scheme 810)
5. Valve Stem Seal Replacing, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-stem-seals-with-cylinder-head).
6. Valve Spring Installation position: Larger diameter down
7. Valve Spring Plate
8. Valve Keys
9. Compression Ring 3 per camshaft Replace if leaking When replacing compression rings, do not spread too widely Install with gaps offset 120° When installing control housing -4-, lightly lubricate compression ring contact surface
10. Nut Tightening specifications and tightening sequence (Scheme 809)
11. Bearing Cap Installed location (Scheme 808)Installation order (Scheme 808)
12. Intake Camshaft Identification (Scheme 806)Removal and installation, refer to «CAMSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshafts) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-radial-play) Run-out maximum 0.01 mm
13. Exhaust Camshaft Identification (Scheme 806)Removal and installation, refer to «CAMSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshafts) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-radial-play) Run-out maximum 0.01 mm
14. Roller Rocker Lever Do not interchange Check roller bearing Before installing, check axial play in camshafts, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-axial-play) Lubricate contact surface For assembly, clip to the hydraulic adjusting element with securing clip -15
15. Securing Clip Check for secure seat
16. Hydraulic Adjusting Elements Do not interchange Before installing, check axial play in camshafts, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__camshaft-measuring-axial-play) Lubricate contact surface
17. Cylinder Head Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-guides-checking) Reface valve seats, refer to «VALVE SEATS, REFACING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-seats-refacing)
18. Intake Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-guides-checking) Rework valve seats, refer to «VALVE SEATS, REFACING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-seats-refacing)
19. Exhaust Valve Do not rework, only lapping is permitted Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-guides-checking) Rework valve seats, refer to «VALVE SEATS, REFACING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valve-seats-refacing)
20. Bolt 8 Nm

Scheme 806

The camshaft marking is located between the cylinder 4 and 5 cam pair.

A - Exhaust camshaft; Identification 022 - Index 101

B - Intake camshaft; Identification 022 - Index 102

Scheme 807

Lightly coat contact surface -shaded- on bearing cap 7 and 8 with adhesive lubricating paste; adhesive lubricating paste.

Scheme 808

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

Scheme 809

Tighten nuts on intake camshaft -A- in 5 stages as follows

1. Install bearing cap 5 and 9 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 5 and 9 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 1 and 13 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 7 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 3 and 11 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Tighten nuts on exhaust camshaft -B- in 5 stages as follows

1. Install bearing cap 6 and 10 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 6 and 10 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 2 and 14 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 8 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 4 and 12 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Scheme 810

1. Guide track, clipped in at control housing
2. Control housing
3. Camshaft Adjustment Valve 1 -N205
4. Camshaft Adjustment Valve 1 (exhaust) -N318
5. Bolt

Scheme 811

Unclip screen -2- on back side of control housing -1- and remove dirt.

VALVE DIMENSIONS

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

VALVE SEATS, REFACING

If a perfect contact pattern is not achieved by grinding the valve seats, reface them.

Note. If an engine with leaking valves is serviced, refacing or replacing valve seats and valves is not sufficient. The valve guides must be checked for wear, especially on engines with high mileage. Refer to VALVE GUIDES, CHECKING . Only refaced valve seats enough to achieve a suitable contact pattern. Calculate maximum permissible reworking dimension before reworking valve seats.

Special tools and workshop equipment required

1. Depth gauge
2. Valve seat reworking device

DETERMINING MAXIMUM ALLOWABLE REWORKING DIMENSION

Note. If valve is replaced during repair, use new valve for measurement.

Insert valve and press firmly against seat.

Using depth gauge, measure distance -a- between end of valve stem and upper cylinder head surface.

Scheme 812

Determine maximum allowable refacing dimension using distance measured and minimum dimension.

Measured distance minus minimum dimension = maximum permissible refaced dimension.

If the maximum permissible refacing dimension is 0 mm or less, repeat measurement using new valve.

If maximum permissible refacing dimension is still 0 mm or less, replace cylinder head.

Note. If refacing dimension is too small, hydraulic valve clearance compensation will not function properly.

Refacing intake valve seat

Scheme 813

a - Dia. 30.6 mm

b - Maximum permissible reworking dimension DETERMINING MAXIMUM ALLOWABLE REWORKING DIMENSION

c - 0.9 to 1.5 mm

d - Maximum dia. 35.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45° valve seat angle

β - 30° upper correction angle

gamma - 60° lower correction angle

Refacing exhaust valve seat

a - Dia. 26.7 mm

b - Maximum permissible reworking dimension DETERMINING MAXIMUM ALLOWABLE REWORKING DIMENSION

c - 1.2 to 1.7 mm

d - Maximum dia. 29.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45° valve seat angle

β - 30° upper correction angle

gamma - 60° lower correction angle

FASTENER TIGHTENING SPECIFICATIONS

Cylinder Head Cover - Tightening Specifications and Tightening Sequence

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

Cylinder Head - Tightening Specifications and Tightening Sequence

Tighten bolts in 4 stages in -1 to 20- sequence as follows

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten bolts by hand.

Tighten the bolts to 30 Nm.

Tighten the bolts to 50 Nm.

Tighten an additional 180° ( 1 / 2 turn).

Upper Timing Chain Cover - Tightening Specifications and Tightening Sequence

1. Pre-tighten the bolts -1- and -2- to 5 Nm.
2. Tighten the bolts -3- to 23 Nm.
3. Tight the bolts -1- and -2- to 10 Nm.

Camshafts - Tightening Specifications and Tightening Sequence

Tighten nuts on intake camshaft -A- in 5 stages as follows

1. Install bearing cap 5 and 9 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 5 and 9 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 1 and 13 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 7 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 3 and 11 to 5 Nm plus an additional 45° ( 1 / 8 turn).

Tighten nuts on exhaust camshaft -B- in 5 stages as follows

1. Install bearing cap 6 and 10 nuts alternately and diagonally as far as stop.
2. Tighten the bearing cap nuts 6 and 10 to 5 Nm plus an additional 45° ( 1 / 8 turn).
3. Tighten the bearing cap nuts 2 and 14 to 5 Nm plus an additional 45° ( 1 / 8 turn).
4. Tighten the bearing cap nuts 8 to 5 Nm plus an additional 45° ( 1 / 8 turn).
5. Tighten the bearing cap nuts 4 and 12 to 5 Nm plus an additional 45° ( 1 / 8 turn).

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763

Procedure

1. Engine oil temperature at least 30 °C / 86 °F.
2. Battery voltage at least 12.5 V.

Switch off ignition.

Remove E-box cover by slide both latches in direction of -arrow-.

Remove Fuel Pump (FP) 2 Relay -J49- -2.1- and Fuel Pump (FP) Relay -J17- -5-.

Scheme 814

Remove ignition coils. Refer to Removal and Installation .

Remove spark plugs with Spark Plug Removal Tool 3122 B.

Check compression pressure with Compression Tester V.A.G 1763; => Operating instructions.

Have a second person completely depress gas pedal and operate starter long enough until tester no longer indicates increase in pressure.

Repeat procedure on each cylinder.

Assembly is in reverse order of removal, note the following

Install spark plugs. Refer to 810 Service Procedures.

Install ignition coils. Refer to Removal and Installation .

Because the relays were removed, malfunctions were saved in the engine control module.

Connect Vehicle Diagnosis, Testing and Information System VAS 5051B.

Start "Guided Functions" operating mode.

Generate readiness code in ECM.

CAMSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

Procedure

Remove the roller rocker levers and the hydraulic adjusting elements. Refer to CAMSHAFTS .

1. The bearing cap of axial bearing for respective camshaft remains installed.

Secure VW 387 with VAS 6079 on cylinder head.

Scheme 815

Axial clearance

1. Wear limit: 0.1 mm.

CAMSHAFT, MEASURING RADIAL PLAY

Procedure

Camshafts, removing. Refer to CAMSHAFTS .

Clean bearing cap and bearing journals.

Removing cam follower. Refer to CAMSHAFTS .

Place Plastigage over entire width of bearing journal or into bearing.

1. Plastigage must rest in center of bearing.

Position the bearing cap and tighten it to 5 Nm. (Scheme 809)without rotating the camshaft.

Reinstall bearing cap.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. Wear limit: 0.1 mm.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

Procedure

Note. If valve is replaced during repair, use new valve for measurement. Due to different stem diameters, only use an intake valve in the intake guide and an exhaust valve in the exhaust guide.

Place valve in valve guide.

1. Valve stem tip must seal with valve guide.

Determine tilt clearance.

Scheme 816

1. Wear limit: 0.8 mm.

If wear limit is exceeded, re-measure using new valves.

If wear limit is still exceeded, replace cylinder head.

Note. The valve guides cannot be replaced.

VALVES, CHECKING

Check valves at stem and seating surface for traces of wear.

If there are clear traces of wear, replace valve.

CYLINDER HEAD COVER

Removing

Remove intake manifold. Refer to Removal and Installation .

Remove bolts -arrows- and lay aside fuel line bracket.

Scheme 817

Remove electrical wiring bracket from upper timing chain cover.

Loosen cylinder head cover bolts in -11 to 1- sequence.

Remove bolts and remove cylinder head cover.

Remove bolts -arrows- and lay aside fuel line bracket

1. Tightening specifications, refer to «CYLINDER HEAD AND CYLINDER HEAD COVER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster), (Scheme 796)

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover seals and bolts if damaged.

Tighten cylinder head cover bolts. (Scheme 796)

Install intake manifold. Refer to Removal and Installation .

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Shop Crane VAS 6100
3. Camshaft Bar T10068 A

Removing

1. Engine installed.

Note. During installation, cable ties must be installed at the same location.

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

Remove intake manifold. Refer to Removal and Installation .

Pull the EVAP cannister -1- in the engine compartment together with the connected hoses upward out of the bracket and lay it to the side.

Scheme 818

Disconnect fuel supply hose -4- by pressing release ring.

Remove coolant hoses -2 and 3-.

Disconnect knock sensor (KS) 1 -G61- electrical sensor -arrow- and free up electrical wiring.

Scheme 819

Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

Scheme 820

Disconnect electrical connectors -1 through 6- on fuel injectors.

Unclip line router on fuel rail -arrows-.

Remove coolant hoses -arrows-.

Scheme 821

Note. The illustration shows the coolant hoses on a vehicle with direct shift automatic transmission (DSG).

Remove coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Remove camshaft timing chain from camshafts. Refer to CAMSHAFT TIMING CHAIN .

Remove heat shield over exhaust manifold -arrows-.

Scheme 822

Remove nuts -1 through 6- and slide front exhaust pipe back slightly from exhaust manifolds.

Scheme 823

Note. Oxygen sensors remain installed.

LOOSEN AND TIGHTEN CYLINDER HEAD BOLTS IN SEQUENCE -1 TO 20

Re-tightening left front engine lifting eye -arrows-.

Scheme 824

Note. The left engine lifting eye was removed to remove the intake manifold.

Engage Lifting Tackle 3033 as follows

Scheme 825

1. Belt pulley side: Position "3".
2. Transmission side: Position "10".

Note. The Lifting Tackle 3033 items labeled with "1 through 12" face toward the transmission side.

Carefully raise cylinder head.

Installing

1. Tightening specifications (Scheme 798)

Note. Replace bolts which have been tightened to torque. Replace sealing rings, seals and self-locking nuts. 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 cylinder head cover. Secure all hose connections with hose clamps appropriate for the model.

Position camshafts at "TDC" before cylinder head is installed.

Scheme 826

1. It must be possible to insert T10068 A into both shaft grooves.

Check again if crankshaft is at "TDC" marking -arrow-.

Scheme 827

Set cylinder head gasket in place.

1. Observe the centering pins in cylinder block.
2. Observe cylinder head seal location, identification: Part number must be visible from intake side.

Set cylinder head in place.

Insert cylinder head bolts and tighten by hand.

Note. The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Tighten cylinder head bolts. (Scheme 798)

Note. Do not tighten cylinder head bolts after repairs.

Installing exhaust manifold. Refer to EXHAUST MANIFOLD .

Install camshaft timing chain INSTALLING (ADJUSTING VALVE TIMING) .

Install cylinder head cover. Refer to CYLINDER HEAD COVER

Install intake manifold. Refer to Removal and Installation .

Follow measures after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

Change engine oil.

Replace coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

TIMING CHAIN UPPER COVER SEAL

Special tools and workshop equipment required

1. Wheel Bearing Assembly Set 3253
2. Fitting Sleeve 3378

Procedure

Remove upper timing chain cover and remove timing chain from camshafts. Refer to CAMSHAFT TIMING CHAIN .

Drive sealing ring out of timing chain upper cover with a drift.

Fit sealing ring with 3378 in timing chain upper cover -1-.

Scheme 828

Pull sealing ring in flush with 3253/6.

Install camshaft timing chain INSTALLING (ADJUSTING VALVE TIMING) .

CAMSHAFT TIMING CHAIN

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Sealant.

Removing the camshaft timing chain

1. Engine installed.

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

Remove intake manifold. Refer to Removal and Installation .

Remove coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Vehicles with engine code BUB

Remove the hose -2- from the secondary air injection (AIR) combination valve.

Scheme 829

Note. Ignore -1-.

Vehicles with engine code CBRA

Disconnect the hose -1- and the vacuum hose -2- from the left Secondary Air Injection (AIR) combination valve.

Scheme 830

Note. Ignore -3- and -arrows-.

All Vehicles

Mark and disconnect electrical connectors

Scheme 831

1. Camshaft Adjustment Valve 1 (exhaust) -N318
2. Camshaft Adjustment Valve 1 -N205
3. Camshaft position sensor -G40
4. Camshaft position (CMP) sensor 2 -G163

Remove Ground (GND) wire -5-.

Disconnect coolant hose -6-.

Remove electrical wiring bracket -arrows-.

Place bracket with electrical wiring toward front.

Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

Adjust crankshaft at vibration damper bolt in direction of engine rotation to "TDC" marking -arrow-.

Cams -A- of cylinder 1 must face each other.

Scheme 832

At the same time, T10068 A must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.

Remove camshaft timing chain tensioner -arrow-.

Scheme 833

Remove the bolts -1, 2 and 3-.

Remove bolts -arrows- and remove guide rail -1-.

Scheme 834

Remove T10068 A.

1. T10068 A must not be inserted when loosening or tightening camshaft adjuster bolts.

Remove intake side camshaft adjuster bolt by counter-holding on camshaft hex head with open-end spanner.

Scheme 835

Remove intake-side camshaft adjuster.

Remove exhaust side camshaft adjuster bolt by counter-holding on camshaft hex head with open-end spanner.

Scheme 836

Remove exhaust-side camshaft adjuster.

Place camshaft timing chain over camshaft adjustment valves.

INSTALLING (ADJUSTING VALVE TIMING)

1. Tightening specifications, refer to «TIMING CHAIN COVERS ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-chain-covers-assembly-overview), (Scheme 801) and «TIMING CHAIN COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster).

Insert guide rail -1- and tighten -arrows-.

Check again if crankshaft is at "TDC" marking -arrow-.

Verify camshaft TDC position

1. Cams -A- of cylinder 1 must face each other.

1. It must be possible to insert camshaft bar T10068 A into both shaft grooves.

If necessary, turn camshafts at hex head surfaces -arrows- to correct position using open end wrench SW 32.

Scheme 837

If necessary, rotate camshaft at hex head -arrows- with open-end spanner into correct position.

Scheme 838

Note. Both camshaft adjusters (identification: 24E on intake side and 32A on exhaust side) can only be bolted in one position on the camshaft mountings -arrows- by an alignment pin.

First install intake side camshaft adjuster

Scheme 839

Rotate sensor wheel -1- clockwise in camshaft adjuster as far as stop -arrow-.

Hand tighten intake side camshaft adjuster in this position to intake camshaft.

Scheme 840

1. Contact surface of sensor wheel at bolt head must be dry when installing.
2. The "24E" marking -1- and the tooth behind it must align with notch -2- in control housing. Markings on control housing (Scheme 804).

Lay camshaft timing chain in this position tightly against intake side camshaft adjuster sprocket.

Starting with the toothed that has the "24E" marking, count exactly 16 rollers to the right on the timing chain. Mark this roller with a color marker.

Scheme 841

Note. Exhaust camshaft adjuster is locked in the rest state. Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If locking mechanism in rest state is not engaged (locked) turn adjuster in both directions by hand until it locks. If that is not possible, replaced camshaft adjuster.

Now insert exhaust camshaft adjuster "32A" with tooth at arrow marking -1- into camshaft roller chain so that the exact, previously counted 16 rollers lie between marking "24E" and "32A" and markings -1- and -2- align.

Scheme 842

Exhaust camshaft adjuster must be able to be inserted easily on exhaust camshaft and be tightened hand-tight.

Check the position of both camshaft adjusters one more time for correct adjustment.

Remove T10068 A.

Tighten bolt on camshaft adjuster intake side by counter-holding with open-end spanner on camshaft hex head.

Tighten bolt on camshaft adjuster exhaust side by counter-holding with open-end wrench on camshaft hex head.

Scheme 843

Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking -arrow-.

1. At the same time, the T10068 A must engage in both shaft grooves.

If camshaft bar cannot be engaged, adjust timing again.

Scheme 844

Note. With cylinder head installed, holes in cylinder head seal are only half visible.

Fill 3 mm bores in cylinder head seal with sealant.

Replace timing chain upper cover sealing ring. Refer to TIMING CHAIN UPPER COVER SEAL .

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

Check whether fitting sleeves -2- and -3- are inserted in upper timing chain cover.

Scheme 845

Insert new sealing ring -1- and new seal -4-.

LIGHTLY COAT CLEAN SEALING SURFACE -SHADED- ON TIMING CHAIN UPPER COVER WITH SEALANT

Coat sealing surface below cylinder head seal with some sealant. Do not bend cylinder head seal.

Note. Timing chain upper cover must be installed with 5 minutes of applying sealant.

Position upper timing chain cover and tighten (Scheme 801).

Install camshaft timing chain tensioner -arrow-.

Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking.

Check timing again.

Install cylinder head cover. Refer to CYLINDER HEAD COVER

Install intake manifold. Refer to Removal and Installation .

Install coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Counter-Holder Tool T10069
3. Sealant.

Removing

Removing engine. Refer to ENGINE, REMOVING .

To separate engine and transmission: Vehicles with manual transmission ENGINE AND MANUAL TRANSMISSION, SEPARATING , vehicles with direct shift automatic transmission (DSG) ENGINE AND DSG TRANSMISSION, SEPARATING .

Remove dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Remove intake manifold. Refer to Removal and Installation .

Remove coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Vehicles with engine code BUB

Remove the hose -2- from the secondary air injection (AIR) combination valve.

Note. Ignore -1-.

Vehicles with engine code CBRA

Disconnect the hose -1- and the vacuum hose -2- from the left Secondary Air Injection (AIR) combination valve.

Note. Ignore -3- and -arrows-.

All Vehicles

Mark and disconnect electrical connectors

1. Camshaft adjustment valve 1 (exhaust) -N318
2. Camshaft adjustment valve 1 -N205
3. Camshaft position sensor -G40
4. Camshaft position (CMP) sensor 2 -G163

Remove Ground (GND) wire -5-.

Disconnect coolant hose -6-.

Remove electrical wiring bracket -arrows-.

Place bracket with electrical wiring toward front.

Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove the oil pan. Refer to OIL PAN .

Adjust crankshaft at vibration damper bolt in direction of engine rotation to "TDC" marking -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, T10068 A must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.

Remove camshaft timing chain tensioner -arrow-.

Remove the bolts -1, 2 and 3-.

Remove lower timing chain cover bolts -arrow-.

Scheme 846

Press crankshaft sealing ring out of timing chain lower cover.

Mark timing chain running direction with arrows using paint -arrows- for reinstallation.

Remove bolts -arrows- and remove guide rail -1-.

Remove camshaft adjuster timing chain from intermediate shaft chain sprocket.

Carefully remove camshaft timing chain behind cylinder head seal rib.

Loosen chain sprocket bolt -arrow- approximately 1 turn.

Scheme 847

Counter hold with T10069 at vibration damper bolt.

Scheme 848

Remove timing mechanism drive chain tensioner -arrows-.

Scheme 849

Remove bolt -arrow- and remove drive chain together with chain sprockets from intermediate shaft.

Installing

1. Tightening specifications, refer to «TIMING CHAIN COVERS ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__timing-chain-covers-assembly-overview) , «TIMING CHAIN COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster) .

When reinstalling a used timing mechanism drive chain, note running direction marking -lower arrow-.

Install drive chain together with large chain sprocket on intermediate shaft.

Scheme 850

1. Installation only possible in one position.

If large chain sprocket cannot be installed, rotate intermediate shaft slightly.

Check if crankshaft is in "TDC" position

1. Milled drive chain sprocket tooth must align with bearing joint -arrow A-.
2. Tab on intermediate shaft sprocket must align with notch -arrow B- on intermediate shaft thrust washer.

Install small chain sprocket on intermediate shaft.

1. Installation only possible in one position.

Replace the chain sprocket bolt for the intermediate shaft.

Tighten chain sprocket bolt -arrow- by hand.

Release locking splines in chain tensioner with small screwdriver -arrow-.

Scheme 851

Press tensioning rail against chain tensioner and tighten chain tensioner in this position -arrows-.

Tighten chain sprocket bolt -arrow-.

Counter hold with T10069 at vibration damper bolt.

Place the timing chain on the camshaft adjuster in such a way that the 2 individual copper color chain sprockets -CA- align with the markings on the camshaft adjuster. It is possible that the intake camshaft adjust will have to be rotated slightly.

Scheme 852

Mount the timing chain on the small chain sprocket. The marking -B- must align with the center copper color chain link -A-.

Insert guide track -1- and tighten bolts -arrows-.

Remove T10068 A.

Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking -arrow-.

Cams -A- of cylinder 1 must face each other.

At the same time, the T10068 A must engage in both shaft grooves.

Note. Marked links now take on an undefined position.

If the camshaft bar cannot be inserted

Repeat valve timing adjustment.

Clean sealant residue from 3 mm bores -arrows- in cylinder head seal.

Note. With cylinder head installed, holes in cylinder head seal are only half visible.

Check whether timing chain lower cover guide pins are inserted in cylinder block.

Lightly coat clean sealing surfaces -shaded- on timing chain lower cover with sealant.

Scheme 853

Note. Timing chain lower cover must be installed with 5 minutes of applying sealant.

Remove lower timing chain cover bolts -arrow-.

Fill 3 mm bores -arrows- in cylinder head seal with sealant.

Note. With cylinder head installed, holes in cylinder head seal are only half visible.

Replace timing chain upper cover sealing ring. Refer to TIMING CHAIN UPPER COVER SEAL .

Check whether fitting sleeves -2- and -3- are inserted in upper timing chain cover.

Insert new sealing ring -1- and new seal -4-.

Lightly coat clean sealing surface -shaded- on timing chain upper cover with sealant.

Coat sealing surface below cylinder head seal with some sealant. Do not bend cylinder head seal.

Note. Timing chain upper cover must be installed with 5 minutes of applying sealant.

Position upper timing chain cover and tighten. (Scheme 801)

Install camshaft timing chain tensioner -arrow-.

Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking.

Check timing again.

Install crankshaft sealing ring. Refer to CRANKSHAFT SEAL, REPLACING .

Install cylinder head cover. Refer to CYLINDER HEAD COVER

Install intake manifold. Refer to Removal and Installation .

Install coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Install oil pan OIL PAN => Installing .

Install dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Install engine. Refer to ENGINE, INSTALLING .

Fill engine oil and check oil level. Refer to OIL LEVEL, CHECKING .

CAMSHAFTS

Special tools and workshop equipment required

1. Camshaft Bar T10068 A
2. Adhesive lubricating paste.

Removing

Note. During installation, cable ties must be installed at the same location.

Remove camshaft timing chain from camshafts. Refer to CAMSHAFT TIMING CHAIN .

Remove control housing -arrows- carefully remove from camshaft sealing rings.

Scheme 854

Remove intake camshaft -A- as follows

1. Remove bearing caps 1 and 13.
2. Remove bearing caps 3 and 11.
3. Remove bearing cap 7.
4. Loosen bearing caps 5 and 9 alternately and in diagonal sequence, and remove.

Remove exhaust camshaft -B- as follows

1. Remove bearing caps 2 and 14.
2. Remove bearing caps 4 and 12.
3. Remove bearing cap 8.
4. Loosen bearing caps 6 and 10 alternately and in diagonal sequence, and remove.

Carefully remove camshafts and place on a clean surface.

Installing

1. Tightening specifications, refer to «VALVETRAIN COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cbra-roadster__valvetrain-component-overview), (Scheme 809).

Install the hydraulic adjusting elements into the cylinder head.

Lay roller rocker lever -1- on valve stem ends and clip in the hydraulic adjusting elements -2-.

Scheme 855

Oil running surfaces of both camshafts.

Camshaft marking between the cylinder 4 and 5 cam pair

A - Exhaust camshaft - Identification 022 - Index 101

B - Intake camshaft - Identification 022 - Index 102

Install the camshafts into the cylinder head in such a way so that the cams -A- on cylinder 1 are pointing toward each other.

Bearing cap location

1. Points -arrow A- of intake and exhaust camshaft bearing caps face outwards.
2. Identification on bearing caps is legible when read from intake side.

Coat contact surface -shaded- of bearing caps 7 and 8 with adhesive lubricating paste.

Tighten camshaft bearing cap. (Scheme 809)

Position camshafts at "TDC".

1. It must be possible to insert T10068 A into both shaft grooves.

If necessary, turn camshafts at hex head surfaces -arrows- to correct position using open end wrench SW 32.

Note. When turning camshafts, crankshaft must not be at TDC with any piston. Valves and/or pistons may be damaged.

Unclip screen -2- on back side of control housing -1- and clean.

Lightly lubricate camshaft sealing ring contact surface in control housing.

Lightly oil sealing ring contact surfaces of camshafts and carefully slide control housing over camshaft sealing rings.

Tighten control housing -arrows-.

Install camshaft timing chain (adjusting timing) INSTALLING (ADJUSTING VALVE TIMING) .

VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING

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. Valve Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
5. Adapter T40012

Procedure

1. Engine removed.

Camshafts, removing. Refer to CAMSHAFTS .

Remove ignition coils. Refer to Removal and Installation .

Remove spark plugs with 3122 B.

Position drift VAS 5161/3 on valve spring plate.

Scheme 856

Loosen stuck valve retainers with a plastic hammer.

Mount the VAS 5161/25 from the VAS 5161 on the cylinder head.

Scheme 857

Tighten guide plane on cylinder head with nut -1-.

Install T40012 with sealing ring in respective spark plug thread and hand tighten.

Connect hose to compressed air.

1. Minimum pressure: 6 bar positive pressure.

Rear valve row

Install VAS 5161/6 with VAS 5161/5 in guide plate.

Scheme 858

Slide VAS 5161/8 in guide plate.

Engage VAS 5161/2 on engaging device and press installation cartridge down.

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

Move knurled screw back and forth slightly.

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

Release pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Front valve row

Tighten VAS 5161/6 with VAS 5161/5 on cylinder head.

Scheme 859

Slide VAS 5161/17 onto installation cartridge VAS 5161/8.

Slide installation cartridge in guide plate.

Engage VAS 5161/2 on engaging device and press installation cartridge down.

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

Move knurled screw back and forth slightly.

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

Release pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Procedure for both valve rows

Pull off valve stem seals with 3364.

Scheme 860

Note. To press on green-colored valve shaft seals from current delivery package, 3365 must be drilled to dia. 10.5 mm. Mark the drilled driver for later reuse.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with Valve Stem Seal Drive 3365.

Remove plastic sleeve.

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

Scheme 861

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.

Scheme 862

1. Installation position: Large diameter -arrow- on valve spring faces toward cylinder head.

Rear valve row

Fasten guide plate on cylinder head again as shown in illustration.

Insert installation cartridge in guide plate.

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

1. The valve retainers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Front valve row

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 retainers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Install camshafts. Refer to CAMSHAFTS .

Install spark plugs.

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 Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
4. Engine and Transmission Holder VAS 6095
5. Cylinder Head Tensioning Device VAS 6419

Procedure

Remove 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.

Insert the VAS 6419 in the VAS 6095.

Scheme 863

Tension the cylinder head on the VAS 6419 as shown in the illustration.

Connect the VAS 6419 to 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 VAS 5161/3 on valve spring plate and loosen stuck valve retainers using a plastic hammer.

Place VAS 5161/25 from VAS 5161 on cylinder head.

Scheme 864

Secure guide plate with a nut -1-.

Rear valve row procedure

Screw VAS 5161/6 with VAS 5161/5 into guide plate.

Scheme 865

Push VAS 5161/8 into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve retainers.

Lightly move knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Front valve row procedure

Screw VAS 5161/6 with VAS 5161/5 onto cylinder head.

Scheme 866

Push the VAS 5161/17 onto the VAS 5161/8.

Push installation cartridge into guide plate.

Hook in VAS 5161/2 at engaging device and press down installation cartridge.

At the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve retainers.

Lightly move knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured in the installation cartridge.

Release pressure fork.

Take out installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Procedure for both valve rows

Pull off valve stem oil seals using 3364.

Note. For pressing on green-colored valve stem seals from delivery program, the 3365 must be drilled to dia. 10.5 mm. Mark the drilled driver for later reuse. A plastic sleeve -A- is supplied with new valve shaft seals.

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

Lightly coat sealing lips of valve stem seal with oil.

Push valve stem seal onto plastic sleeve.

Carefully press valve stem oil seal onto valve guide using 3365.

Remove plastic sleeve again.

If the valve keys were removed from the installation cartridge, they must be inserted into VAS 5161/18 next.

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

Install valve spring and valve spring plate.

Installed position of valve spring

1. The larger diameter -arrow- faces toward cylinder head.

Rear valve row procedure

Fasten the guide plate to cylinder head again as shown in illustration.

Insert installation cartridge into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.

Release pressure fork with the knurled bolt still pulled.

Front valve row procedure

Insert installation cartridge with knurled spacer wheel into guide plate.

Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve retainers.

Release pressure fork with the knurled bolt still pulled.

Install camshafts. Refer to CAMSHAFTS .

Install sparks plugs.

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Scheme 867

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. Valve Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
5. Adapter T40012

Scheme 868

Special tools and workshop equipment required

1. Valve Seal Removal Tool 3364
2. Valve Stem Seal Driver 3365
3. Valve Retainer Disassembly and Assembly Device VAS 5161 with Guide Plate VAS 5161/25
4. Engine and Transmission Holder VAS 6095
5. Cylinder Head Tensioning Device VAS 6419

Special tools and workshop equipment required

Scheme 869

Scheme 870

Scheme 871

Scheme 872

Scheme 873

Scheme 874

Scheme 875

Scheme 876

Scheme 877

Scheme 878

1. Spark Plug Removal Tool 3122 B
2. Compression Tester V.A.G 1763
3. Dial Gauge Holder VW 387
4. Dial Gauge VAS 6079
5. Lifting Tackle 3033
6. Shop Crane VAS 6100
7. Camshaft Bar T10068 A
8. Wheel Bearing Assembly Set 3253
9. Fitting Sleeve 3378
10. Counter-Holder Tool T10069

See also:
• SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW
• DUAL-MASS FLYWHEEL COMPONENT OVERVIEW
• COOLANT THERMOSTAT HOUSING
• Removal and Installation
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• EXHAUST MANIFOLD
• [For transmission(s) 02E] Removal and Installation
• ENGINE, REMOVING
• ENGINE AND MANUAL TRANSMISSION, SEPARATING
• ENGINE AND DSG TRANSMISSION, SEPARATING
• DUAL MASS FLYWHEEL
• OIL PAN
• CRANKSHAFT SEAL, REPLACING
• ENGINE, INSTALLING
• OIL LEVEL, CHECKING
• CYLINDER HEAD
• CYLINDER HEAD COVER
• TIMING CHAIN UPPER COVER SEAL
• LIGHTLY COAT CLEAN SEALING SURFACE -SHADED- ON TIMING CHAIN UPPER COVER WITH SEALANT
• CAMSHAFTS
• CAMSHAFT TIMING CHAIN
• TIMING MECHANISM DRIVE CHAIN AND CAMSHAFT TIMING CHAIN
• VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED, REPLACING
• CAMSHAFT, MEASURING AXIAL PLAY
• CAMSHAFT, MEASURING RADIAL PLAY
• VALVE GUIDES, CHECKING
• VALVE SEATS, REFACING
• VALVE DIMENSIONS
• DETERMINING MAXIMUM ALLOWABLE REWORKING DIMENSION
• INSTALLING (ADJUSTING VALVE TIMING)
• TIMING CHAIN COVERS ASSEMBLY OVERVIEW
• VALVETRAIN COMPONENT OVERVIEW