Home ReviewsRefund
Home/Audi/TT/Audi TT 8J рестайлинг (2010-2014)/Repair manual/Mechanical/2.0l - Cylinder Head, Valvetrain - Engine Code(s): Cdma (co…
Contents Section: Mechanical All sections

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

Mechanical 95 illustrations ~6007 words

Scheme 422

Scheme 422: TOOTHED BELT DRIVE OVERVIEW
Scheme 422: TOOTHED BELT DRIVE OVERVIEW
  1. Bolt 9 Nm
  2. Upper Toothed Belt Guard
  3. Bolt Replace 50 Nm plus an additional 180° turn Loosen and tighten with retainer 3036
  4. Camshaft Sprocket Installation position secured by the woodruff key -7
  5. Bolt 9 Nm Insert with locking compound; Locking compound..
  6. Rear Toothed Belt Guard
  7. Woodruff Key Make sure it is secure
  8. Nut 23 Nm
  9. Tensioning Roller
  10. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-coupe__coolant-pump)
  11. O-ring Replace
  12. Bolt 23 Nm
  13. Damper Roller
  14. Bolt Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-coupe__coolant-pump-and-coolant-thermostat-with)
  15. Bolt 33 Nm
  16. Damper Roller
  17. Sealing Flange Removing and Installing, refer to «SEALING FLANGE, BELT PULLEY SIDE»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cdma-coupe__sealing-flange-belt-pulley-side)
  18. Diamond Disc Between the toothed belt pulley and crankshaft Removing and installing
  19. Crankshaft Toothed Belt Sprocket Removing and installing (Scheme 423)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° turn Do not oil
  21. Toothed Belt Before removing, mark direction of rotation using chalk or felt-tip marker Check for wear Removing, refer to «TOOTHED BELT»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__toothed-belt) Installing (adjusting valve timing) «INSTALLING (ADJUSTING VALVE TIMING)»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe)
  22. Lower Toothed Belt Guard
  23. Bolts 9 Nm Quantity: 7
  24. Engine Support
  25. Bolt Tightening specifications, refer to «ENGINE AND TRANSMISSION MOUNTS OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-engine-assembly-engine-codes-cdma-coupe)

Scheme 423

Scheme 423
Scheme 423

Use the counter support 3415 to loosen or tighten the crankshaft toothed belt pulley bolt.

Note. Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil.

Place a new diamond disc between the toothed belt pulley and the crankshaft when installing.

Scheme 424

Scheme 424: CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW
Scheme 424: CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW
  1. Bolt Replace if the seal is damaged Tightening sequence (Scheme 425)
  2. Cylinder Head Cover
  3. Gasket Replace if damaged or leaking
  4. Pressure Regulator Valve For crankcase ventilation
  5. Cover
  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 and installing, refer to «CAMSHAFT ADJUSTMENT VALVE 1»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-adjustment-valve-1)
  12. Seal Removing and installing
  13. Bolt 9 Nm
  14. Harness Mount
  15. Seal Replace if damaged or leaking
  16. Bolt 9 Nm
  17. Housing For the drive chain
  18. Gasket Replace
  19. Engine Lifting Eye
  20. Bolt 23 Nm
  21. Threaded Pin 9 Nm For intake manifold
  22. Partition Plate
  23. Cylinder Head Gasket Replace Note installation position: The part number faces the cylinder head
  24. Bolt 9 Nm
  25. Camshaft Position Sensor -G40
  26. Seal
  27. Threaded Pin 15 Nm For the tensioning roller
  28. Threaded Pin 17 Nm For exhaust manifold
  29. Cylinder Head Removing and Installing, refer to «CYLINDER HEAD»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe) (Scheme 427) (Scheme 428)After replacing, change coolant and engine oil
  30. Bolt Replace Follow the sequence when loosening «LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 10»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe) Tightening specification and sequence (Scheme 426)

Scheme 425

Scheme 425
Scheme 425
Tighten the bolts in the following sequence: -1 to 14- in 2 steps:-- Install bolts by hand as far as the stop.-- Tighten to 10 Nm.

Scheme 426

Scheme 426
Scheme 426
Tighten bolts in 3 stages in -1 to 10- sequence as follows:-- Tighten to 40 Nm.-- Tighten an additional 90°.-- Tighten an additional 90°.

Scheme 427

Scheme 427
Scheme 427

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

  1. Maximum permissible distortion: 0.05 mm.

Scheme 428

Scheme 428
Scheme 428

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

  1. Minimum dimension -a- = 139.20 mm.

VALVETRAIN OVERVIEW

CAUTIONRisk of damaging valves and piston heads after working on the valvetrain. The motor must not be started for about 30 minutes after installing the camshafts because the hydraulic equalization elements must seat themselves. To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

Scheme 429

Scheme 429
Scheme 429
  1. Bolt Replace Loosen and tighten with retainer 3036 Tightening specifications «TOOTHED BELT DRIVE OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe)
  2. Toothed Belt Camshaft Gear
  3. Shaft Seal For exhaust camshaft Removing and installing, refer to «EXHAUST CAMSHAFT SEAL»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__exhaust-camshaft-seal)
  4. Cylinder Head
  5. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-guides-checking)
  6. Valve Stem Seal Replace, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-stem-seals-with-cylinder-head), «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-stem-seals-with-cylinder-head)
  7. Valve Spring
  8. Valve Spring Plate
  9. Valve Keys
  10. Hydraulic Adjusting Elements With roller rocker lever and clip Mark the installed position for installation later Lubricate contact surfaces
  11. Fitted Key Make sure it is secure
  12. Exhaust Camshaft Removing and Installing, refer to «CAMSHAFTS»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshafts) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-measuring-radial-play) Maximum run out: 0.04 mm
  13. Guide Frame With integrated camshaft bearings Do not rework the sealing surfaces, only clean them. Only replace together with the cylinder head.
  14. Bolt Replace Tightening specification and sequence (Scheme 430)
  15. Camshaft Adjuster Removing and installing, refer to «CAMSHAFT ADJUSTER»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-adjuster)
  16. Bolt Replace 20 Nm plus an additional 45° turn
  17. Intake Camshaft Removing and installing, refer to «CAMSHAFTS»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshafts) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-measuring-axial-play) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-measuring-radial-play) Maximum run out: 0.04 mm
  18. Chain Tensioner Removing, refer to «CAMSHAFT ADJUSTER»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__camshaft-adjuster) Before removing, secure with locking pin T10115
  19. Drive Chain
  20. Bolt Replace 9 Nm Self-locking
  21. Bolt Tightening specifications «CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe)
  22. Camshaft Position Sensor -G40- Illustration does not correspond to version in vehicle
  23. Exhaust Valve Do not rework, only lapping is permitted For the correct valve dimensions, refer to «VALVE DIMENSIONS»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-dimensions) Valve Guides, Checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-guides-checking)
  24. Intake Valve Do not rework, only lapping is permitted For the correct valve dimensions, refer to «VALVE DIMENSIONS»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-dimensions) Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valve-guides-checking)
  25. Cover Replace Removing: With the guide frame installed, pierce through one side of the cover with an awl and pry it out. Installing: Press in 1 to 2 mm without sealant using the thrust piece 3334

Scheme 430

Scheme 430
Scheme 430

Replace the guide frame bolts.

Tighten bolts in 3 stages in -1 to 6- sequence as follows

Install bolts by hand as far as stop.

  1. The guide frame must be in contact with the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90°.

VALVE DIMENSIONS

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

DimensionIntake ValveExhaust Valve
Diameter aMm33.85 ± 0.1028.0 ± 0.1
Diameter bMm5.98 ± 0.015.96 ± 0.01
CMm104.0 ± 0.2101.9 ± 0.2
ΑAngle°4545
WARNINGRisk of injury if exhaust valves with sodium filling are disposed of improperly. Cut exhaust valve with sodium filling into 2 parts with a metal saw between shaft center and valve plate. While doing this, do not come into contact with water. Throw at the most 10 such sawed exhaust valves in a bucket filled with water and step back immediately. When there is contact with water, a sudden chemical reaction occurs which burns the sodium filling. The treated parts may then be discarded through conventional disposal channels.

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Camshaft Adjuster (1)20 + 45°
Camshaft Adjustment Valve 14
Camshaft Position Sensor9
Camshaft Sprocket (1)50 + 180°
Chain Tensioner (1)9
Coolant Pump15
Crankshaft Toothed Belt Sprocket (1)90 + 90°
Damper Roller23
Engine Lifting Eye23
Harness Mount9
Housing for the Drive Chain9
Lower Toothed Belt Guard9
Pressure Regulator Valve4
Rear Toothed Belt Guard (2)9
Tensioning Roller, Nut23
Threaded Pin for Exhaust Manifold17
Threaded Pin for Intake Manifold9
Threaded Pin for Tensioning Roller15
Toothed Belt Camshaft Gear (1)50 + 180°
Upper Toothed Belt Guard9
(1) Replace (2) Insert with locking compound
(1)Replace
(2)Insert with locking compound

Cylinder Head Cover, Tightening Specifications and Sequence

Tighten the bolts in the following sequence: -1 to 14- in 2 steps

Install bolts by hand as far as the stop.-- Tighten to 10 Nm.

Cylinder Head, Tightening Specifications and Sequence

Tighten bolts in 3 stages in -1 to 10- sequence as follows

Tighten to 40 Nm.-- Tighten an additional 90°.-- Tighten an additional 90°.

Guide Frame Tightening Specifications and Sequence

Replace the guide frame bolts.

Tighten bolts in 3 stages in -1 to 6- sequence as follows

Install bolts by hand as far as stop.

  1. The guide frame must be in contact with the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90°.

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.

Disconnect the injector valve connector -2-.

Scheme 431

Scheme 431
Scheme 431

Note. Ignore -1, 3, 4 and 5-.

Remove ignition coils. Refer to Removal and Installation .

Remove spark plugs with 3122 B.

Check compression pressure with the V.A.G 1763.

Have a second technician press the accelerator pedal down all the way while operating the starter until the pressure increase is no longer displayed on the tester.

Repeat procedure on each cylinder.

Compression PressureBar Pressure
New10.0 to 14.0
Wear limit7.0
Maximum difference between cylinders3.0

Assembling

Assemble in reverse order of disassembling. Note the following

Install spark plugs. Refer to SPARK PLUGS, REMOVING AND INSTALLING .

Install ignition coils. Refer to Removal and Installation .

Faults are saved in Engine Control Module (ECM) when electrical connectors are disconnected

Connect vehicle diagnosis, testing and information systemVAS 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 0-10 mm VAS 6079

Procedure

Remove the guide frame. Refer to CAMSHAFTS .

Place camshaft to be checked in guide frame.

Secure the VAS 6079 to cylinder head with the VW 387.

Press camshaft against dial gauge by hand.

Scheme 432

Scheme 432
Scheme 432

Set dial gauge to "0".

Press camshaft off dial gauge and read the value

  1. Axial clearance: 0.05 to 0.17 mm.

CAMSHAFT, MEASURING RADIAL PLAY

Procedure

Removing cam follower. Refer to CAMSHAFTS .

Clean the bearing and the bearing journals.

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

  1. Plastigage must rest in center of bearing.

Position the guide frame and tighten to 8 Nm. (Scheme 430)without rotating camshaft.

Install the guide frame.

Compare width of Plastigage with calibrated scale.

Radial clearance

Bearing diameter 24 mm: 0.024 to 0.066 mm.

Bearing diameter 32 mm: 0.030 to 0.051 mm.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

  1. Dial Gauge Holder VW 387
  2. Dial Gauge 0-10 mm 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 the tilt clearance.

Scheme 433

Scheme 433
Scheme 433
  1. Wear limit: 0.8 mm.

If wear limit is exceeded, measure using new valves.

Replace the cylinder head if the wear limit is still exceeded.

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.

TOOTHED BELT

Special tools and workshop equipment required

  1. Engine Support Bridge 10 - 222 A
  2. Shackle 10 - 222 A /12
  3. Adapter T40093/6 qty. 2

Removing

Remove the engine cover -arrows-.

Scheme 434

Scheme 434
Scheme 434

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

Remove the right front wheel.

Remove the right noise insulation -arrows-.

Scheme 435

Scheme 435
Scheme 435

Loosen the front section of the wheel housing liner and push it to the rear. Refer to Removal and Installation .

Remove the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

Remove the bolts -arrows- and the EVAP canister bracket.

Scheme 436

Scheme 436
Scheme 436

Note. Ignore -1-.

Remove the coolant hose -arrow-.

Scheme 437

Scheme 437
Scheme 437

Remove the coolant hoses -1- and -2-.

Scheme 438

Scheme 438
Scheme 438

Free up the electrical wiring harness on the coolant reservoir.

Scheme 439

Scheme 439
Scheme 439

Disconnect the connector -1- from the engine coolant level warning switch -F66-.

Remove the bolts -arrows- and remove the coolant reservoir.

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

Scheme 440

Scheme 440
Scheme 440

Remove the bolt and nut -arrows- and push the front coolant pipe to the side.

Scheme 441

Scheme 441
Scheme 441

Place the 10 - 222 A on upper edge of web plates with the following tool parts

Scheme 442

Scheme 442
Scheme 442
  1. Engine brackets 10 - 222 A /1, quantity: 2
  2. Spindle 10 - 222 A /11
  3. Shackle 10 - 222 A /12
  4. Adapter T40093/6 qty. 2

Attach the 10 - 222 A /11 and 10 - 222 A /12 to the engine lifting eye.

Tighten the spindle to tension the engine/transmission.

Remove the bolts -1- and -2- and the connecting brace.

Scheme 443

Scheme 443
Scheme 443

Remove the bolts -3 through 6- and the engine mount.

Remove the bolts -1, 2 and 3-.

Scheme 444

Scheme 444
Scheme 444

Note. The bolt is reached -2- from the wheel housing side.

CAUTIONDanger of damaging components and hoses. Be careful not to damage any parts or to overbend any hoses when lifting the engine.

Lift the engine by the 10 - 222 A until it is possible to remove the engine support.

CAUTIONComponents could be destroyed by the toothed belt jump off. Only rotate the crankshaft in the direction of engine rotation.

Turn the crankshaft by the toothed belt crankshaft sprocket bolt until the camshaft sprocket is at "TDC".

Scheme 445

Scheme 445
Scheme 445
  1. The marking on the camshaft sprocket must align with the arrow on the toothed belt guard -top arrow-.
  2. The notch on the vibration damper must align with the arrow on the toothed belt guard -bottom arrow-.

Remove vibration damper. Refer to VIBRATION DAMPER .

CAUTIONThe engine could be damaged. The "TDC" markings must align before the vibration damper can be removed. Crankshaft must not be rotated any more until "TDC" position is marked with an assisting mark.

Remove the lower toothed belt guard -arrows-.

Scheme 446

Scheme 446
Scheme 446

Mark the "TDC" -arrow-.

Scheme 447

Scheme 447
Scheme 447
CAUTIONA used toothed belt could be destroyed if the running direction is reversed. Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.

Loosen the tensioning roller and remove the toothed belt.

Scheme 448

Scheme 448: INSTALLING (ADJUSTING VALVE TIMING)
Scheme 448: INSTALLING (ADJUSTING VALVE TIMING)
  1. For the correct tightening specifications, refer to «TOOTHED BELT DRIVE OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe) .
CAUTIONRisk of damaging valves and piston crowns. If camshafts are being rotated, crankshaft may not rest with any piston at "TDC". The engine must be no more than warm to touch.

Make sure the camshaft and crankshaft are at "TDC"

  1. The markings on the camshaft -top arrow- and crankshaft -bottom arrow- must align.

When reinstalling the toothed belt, note running direction marking

Scheme 449

Scheme 449
Scheme 449
  1. Crankshaft, tensioning roller, camshaft, coolant pump and idler roller -arrow-.

Make sure the tensioning roller fits correctly inside the cylinder head.

Scheme 450

Scheme 450
Scheme 450
  1. The bracket -arrow- must engage into the cut-out in the cylinder head.

Tension the toothed belt as follows

Rotate the eccentric pulley clockwise using a socket wrench -arrow- until the notch -2- is above the tab -3- (toothed belt over-tensioned).

Scheme 451

Scheme 451
Scheme 451

Release the eccentric pulley back to its starting position (toothed belt relaxed).

Rotate the eccentric pulley clockwise using a socket wrench -arrow- until the notch -2- is opposite the tab -3-.

Tighten the tensioning roller nut -1-.

CAUTIONComponents could be destroyed by the toothed belt jump off. Only rotate the crankshaft in the direction of engine rotation.

Turn the crankshaft by the toothed belt pulley bolt 2 turns in the direction of engine rotation until the crankshaft is once again at "TDC".

  1. The last 45° ( 1 / 8 turn) must be turned uninterrupted.

Check the toothed belt tension

  1. The notch -2- and the tab -3- must align.

Re-tension the toothed belt if necessary.

Valve Timing, Checking

  1. The markings on the camshaft -top arrow- and crankshaft -bottom arrow- must align.

If the markings do not align, repeat setting the valve timing.

The rest of the installation is performed in reverse order of removal, noting the following

Install the lower toothed belt guard. Refer to TOOTHED BELT DRIVE OVERVIEW .

Install vibration damper. Refer to VIBRATION DAMPER .

Check the valve timing one more time

  1. The marking on the camshaft sprocket must align with the arrow on the toothed belt guard -top arrow-.
  2. The notch on the vibration damper must align with the arrow on the toothed belt guard -bottom arrow-.

Install the engine support and the engine mount. Refer to ENGINE AND TRANSMISSION MOUNTS OVERVIEW and adjust SUBFRAME MOUNT, ADJUSTING .

Install the front right coolant pipe. Refer to RIGHT FRONT COOLANT PIPE .

Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER .

CAMSHAFT ADJUSTMENT VALVE 1

Removing

Remove the engine cover -arrows-.

Disconnect the connector -1-.

Scheme 452

Scheme 452
Scheme 452

Remove the wiring harness bracket -2-.

Remove the bolt -3-.

CAUTIONDanger of damaging the wire. Do not pull out camshaft adjustment valve 1 -N205- at connector.

Remove the bolts -arrows- and camshaft adjustment valve 1 from the drive chain housing.

Scheme 453

Scheme 453
Scheme 453

Installing

  1. For the correct tightening specifications, refer to «CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe) .

Note. Replace the seal. Clean the camshaft adjustment valve 1 and the drive chain housing.

CAUTIONProtect the camshaft adjustment valve 1 from shocks and impact stress. Remove the new camshaft adjustment valve 1 from its packaging just before installing it.

Coal the sealing ring with engine oil.

Carefully install the camshaft adjustment valve 1 into the drive chain housing and push it all the way by hand horizontally to the valve axle.

The rest of the installation is performed in reverse order of removal, noting the following

Install the coolant ventilation line. Refer to COOLANT PIPES OVERVIEW .

CYLINDER HEAD COVER

Removing

Remove the engine cover -arrows-.

Remove the bolts -arrows- and move the toothed belt cover to the side.

Remove ignition coils. Refer to Removal and Installation .

Remove bolt -arrow-.

Scheme 454

Scheme 454
Scheme 454

Loosen the hose clamps -1- and -3- and move the air guide pipe to the side with the hose still connected -2-.

Remove the vacuum line -1- from the cylinder head cover.

Scheme 455

Scheme 455
Scheme 455

Remove the bolts -arrows- and then remove the crankcase housing ventilation pressure regulator valve.

Remove the Evaporative Emission (EVAP) canister line -2- from the cylinder head cover.

Scheme 456

Scheme 456
Scheme 456

Remove the bolts -3- and then remove the crankcase ventilation tube and heat shield from the cylinder head cover by loosening the hose clamp -1-.

Loosen the cylinder head cover bolts in the following sequence: -14 to 1-.

Remove the bolts and the cylinder head cover.

Installing

Installation is done is reverse order, observe the following

  1. Tightening specifications, refer to «CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe), (Scheme 425).

Note. Replace the cylinder head seal if it is damaged. Replace the cylinder head cover bolts when replacing the damaged seal. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Tighten cylinder head cover bolts. (Scheme 425)

Install the crankcase ventilation line. Refer to TURBOCHARGER OVERVIEW .

Tighten the upper toothed belt guard. Refer to TOOTHED BELT DRIVE OVERVIEW .

Install ignition coils. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Hose Clip Pliers V.A.G 1921
  2. Polydrive Bit and Drive Socket T10070

Removing

  1. Engine installed.

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

Remove the engine cover -arrows-.

Remove fan shroud. Refer to FAN SHROUD .

Remove the turbocharger. Refer to TURBOCHARGER .

WARNINGRisk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
CAUTIONFollow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Remove the protective boot -2- and disconnect the fuel hose by pressing the release ring.

Scheme 457

Scheme 457
Scheme 457

Remove the hose -1-.

Release the EVAP canister -B arrow-, remove it upward -A arrow- and lay it aside.

Remove the bolt and nut -arrows- and then push the front right coolant pipe to the side with the coolant hoses still connected.

Remove the double bolt -arrow- for the oil dipstick guide tube.

Scheme 458

Scheme 458
Scheme 458

Disconnect the connector -3-.

Scheme 459

Scheme 459
Scheme 459

Remove bolt -arrow-.

Remove the hose -2-.

Loosen the hose clamp -1- and then remove the turbocharger recirculating valve -N249- with the hose still connected -4- from the air guide pipe and lay it to the side.

Disconnect the connector -arrow- on the charge air pressure sensor -G31-.

Scheme 460

Scheme 460
Scheme 460

Remove the bolt -1- and nut -4-.

Loosen the hose clamp -2- and remove the air guide pipe.

Note. Ignore -3-.

Disconnect the connector -1- on the Intake Air Temperature (IAT) Sensor 2 -G299-.

Scheme 461

Scheme 461
Scheme 461

Note. Ignore -arrow-.

Disconnect the connector -1-.

Scheme 462

Scheme 462
Scheme 462

Remove bolts -arrows- and remove throttle valve control module -J338-.

Remove the nut -2- and screw -1- and remove the intake manifold support.

Scheme 463

Scheme 463
Scheme 463

Disconnect the connectors on the low fuel pressure sensor -G410- -1- and on the fuel pressure regulator valve -N276- -2-.

Scheme 464

Scheme 464
Scheme 464

Free up electrical wires.

Note. Ignore -arrows-.

Remove the crankcase ventilation hose -1- from the oil separator by pressing the release buttons.

Disconnect the connectors

2 - For the injector valves, remove the connectors from the bracket

3 - For evaporative emission (EVAP) canister purge regulator valve 1 -N80

4 - Intake flap motor -V157

5 - Fuel pressure sensor -G247- and camshaft position sensor -G40-, remove the connectors from the bracket

Disconnect the connector -1-.

Remove the wiring harness -2- from the bracket.

Note. Ignore -3-.

Free up the wiring harness -arrows- and remove the bracket bolt -1-.

Scheme 465

Scheme 465
Scheme 465

Remove ground (GND) wire -1-.

Scheme 466

Scheme 466
Scheme 466

Disconnect the connector -2-.

Remove the coolant hoses and the vacuum hoses -arrows-.

Toothed belt, removing. Refer to TOOTHED BELT .

Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

Scheme 467

Scheme 467: LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 10
Scheme 467: LOOSEN THE CYLINDER HEAD BOLTS IN THE FOLLOWING SEQUENCE -1 THROUGH 10

Remove bolts and remove cylinder head.

Installing

  1. Tightening specifications, refer to «CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe), (Scheme 426).
CAUTIONThe sealing surfaces could be damaged. Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Risk of damaging cylinder block. No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block. Risk of leaks in cylinder head seal. Carefully remove sealant residue 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. To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully. Risk of damaging open valves. If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts, sealing rings, seals and O-rings. If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the camshaft housing. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

Align the marking on the toothed belt camshaft pulley with the marking on the toothed belt guard -top arrow-.

Scheme 468

Scheme 468
Scheme 468
  1. The cams -A- on both camshafts are symmetrical to each other.
  2. The notches -arrows- on both camshafts must align.

Clean the sealing surfaces; they must be free of oil and grease.

Make sure the crankshaft is still at "TDC" and then turn it back 45° opposite the engine rotation.

Set cylinder head gasket in place.

Scheme 469

Scheme 469
Scheme 469
  1. Installed position: It must be possible to read the part number.
  2. Note the sleeves in the cylinder block.

Set cylinder head in place.

Tighten the cylinder head bolts. (Scheme 426)

Note. Do not tighten cylinder head bolts after repairs.

Install cylinder head cover. Refer to CYLINDER HEAD COVER .

Rotate the crankshaft back to "TDC".

Install toothed belt (adjust timing) INSTALLING (ADJUSTING VALVE TIMING) .

Install the intake manifold support and throttle valve control module -J338-. Refer to Removal and Installation .

Tighten the oil dipstick guide tube. (Scheme 470)

Install the air guide pipe. Refer to CHARGE AIR COOLER OVERVIEW .

Install the right front coolant pipe. Refer to RIGHT FRONT COOLANT PIPE .

Install the turbocharger. Refer to TURBOCHARGER .

Install fan shroud. Refer to FAN SHROUD .

Electrical connections and routing. Refer to Wiring Diagram.

Change engine oil. Refer to MAINTENANCE PROCEDURES

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

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. M12 nut, quantity: 2

Procedure

  1. Tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valvetrain-overview)

Toothed belt, removing. Refer to TOOTHED BELT .

Loosen the camshaft toothed belt sprocket bolt with the 3036.

Scheme 470

Scheme 470
Scheme 470

Remove the camshaft toothed belt sprocket with the T40001 and the claws T40001/6 and T40001/7.

Scheme 471

Scheme 471
Scheme 471

To guide seal puller, thread adapter 2085/2 in camshaft by hand until stop.

Scheme 472

Scheme 472
Scheme 472

Loosen the inner section of the 2085 two turns (approximately 3 mm) from the outer section and secure it with the knurled bolt.

Lubricate the seal remover threaded head, position it, and then install it into the shaft seal as far as possible using strong force.

Scheme 473

Scheme 473
Scheme 473

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

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

Clean the shaft seal running and sealing surfaces.

Note. Do not oil the sealing lip and the outer edge of seal before installing.

Cover the groove on the camshaft cone with adhesive tape -arrow-.

Scheme 474

Scheme 474
Scheme 474

Place two M12 nuts -1- under the bolt head T10071/4.

Scheme 475

Scheme 475
Scheme 475

Press the shaft seal with guide sleeve T10071/3 and bolt T10071/4 in as far as the stop.

Note. Make sure the fitting key for the camshaft toothed belt sprocket is seated correctly.

CAUTIONRisk of damaging valves and piston crowns. If camshafts are being rotated, crankshaft may not rest with any piston at "TDC". The engine must be no more than warm to touch.

Tighten the camshaft toothed belt sprocket bolt with the 3036.

Install toothed belt (adjust timing) TOOTHED BELT DRIVE OVERVIEW .

CAMSHAFT ADJUSTER

Special tools and workshop equipment required

  1. Socket T40080
  2. Camshaft Clamp T10252
  3. Toothed Belt Tensioner T10020
  4. Locking Pin T10115
  5. Retainer 3036
  6. Hose Clamps Up to 25 mm Dia.3094

Removing

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

Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

Remove vacuum pump. Refer to Removal and Installation .

Remove the bolts -arrows-.

Scheme 476

Scheme 476
Scheme 476

Note. Ignore -1-.

Clamp off coolant hoses -1- and -2- with 3094 and remove them.

Scheme 477

Scheme 477
Scheme 477

Remove the bolt -3- and press the coolant ventilation line back slightly.

Disconnect the connector -1-.

Remove the wiring harness bracket -2-.

Note. Ignore -3-.

Free up the wiring harness -arrows- and remove the bracket bolt -1-.

Remove the bolts -arrows- and the camshaft adjuster housing.

Scheme 478

Scheme 478
Scheme 478
CAUTIONComponents could be destroyed by the toothed belt jump off. Only rotate the crankshaft in the direction of engine rotation.

Turn the crankshaft by the toothed belt crankshaft sprocket bolt until the camshaft sprocket is at "TDC".

  1. The marking on the camshaft sprocket must align with the arrow on the toothed belt guard -top arrow-.
  2. The notch on the vibration damper must align with the arrow on the toothed belt guard -bottom arrow-.
  1. The cams -A- on both camshafts are symmetrical to each other.
  2. The notches -arrows- on both camshafts must align.

Position the T10252 and tighten it -arrows- as illustrated.

Scheme 479

Scheme 479
Scheme 479

Also counterhold the camshaft toothed belt sprocket with the 3036.

Loosen the camshaft adjuster bolt approximately 1 / 2 turn with the T40080.

Scheme 480

Scheme 480
Scheme 480

Press the chain tensioner down -arrow A- and secure with the T10115 -arrow B-.

Scheme 481

Scheme 481
Scheme 481

Remove the camshaft adjuster bolt and remove the camshaft adjuster with the drive chain.

Installing

  1. For the correct tightening specifications, refer to «VALVETRAIN OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cdma-coupe__valvetrain-overview)
  2. The camshafts are secured with the T10252

Note. Replace the camshaft adjuster bolt.

Place the drive chain on the camshaft adjuster.

Hold the camshaft adjuster in front of the exhaust camshaft as follows

Scheme 482

Scheme 482
Scheme 482
  1. The groove -A- and pin -B- must align.

With the drive chain in this position, first route it on the intake camshaft chain sprocket at the top -arrow-.

Scheme 483

Scheme 483
Scheme 483

Rotate the intake camshaft clockwise -arrow A- slowly with the T10020 until the camshaft adjuster fits on the camshaft.

Scheme 484

Scheme 484
Scheme 484

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

Tighten the camshaft adjuster bolt with the T40080.

Installation is done is reverse order, observe the following

Install the coolant ventilation line. Refer to COOLANT PIPES OVERVIEW .

Install the vacuum pump. Refer to Removal and Installation .

Install cylinder head cover. Refer to CYLINDER HEAD COVER

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

CAMSHAFTS

Special tools and workshop equipment required

  1. Puller T40001
  2. Retainer 3036
  3. Sealant remover (commercially available)
  4. Sealant.

Removing

Note. Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked. Camshaft bearings are integrated in the cylinder head and guide frame. Before removing guide frame, tension on toothed belt must be released. Replace the camshaft seal and cover when the guide frame is removed.

Removing camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Toothed belt, removing. Refer to TOOTHED BELT .

Loosen the camshaft toothed belt sprocket bolt with the 3036.

Remove the camshaft toothed belt sprocket with the T40001 and the claws T40001/6 and T40001/7.

Remove the rear toothed belt guard bolts -arrows-.

Scheme 485

Scheme 485
Scheme 485

Tilt the rear toothed belt guard away from the cylinder head slightly.

Loosen the guide frame bolts in the following sequence: -6 to 1-.

Remove the bolts and carefully remove the guide frame and lay it on a soft surface on the workbench.

Remove the camshafts with the drive chain from the cylinder head and lay on a clean surface.

Installing

  1. Tightening specifications (Scheme 430)

Note. Replace guide frame bolts.

CAUTIONRisk of contaminating lubricating system and bearing. Cover open parts of engine.

Remove reside on the cylinder head and guide frame with sealant remover (commercially available).

Clean the sealing surfaces; they must be free of oil and grease.

Make sure all of the roller rocker levers lie on the valve stem ends correctly.

Lubricate the running surfaces of both camshafts.

Place the drive chain on the chain sprockets for the removed camshaft as follows

Scheme 486

Scheme 486
Scheme 486
  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 the camshafts in the cylinder head and the chain tensioner together with the drive chain.

Check the camshaft "TDC" position again

Scheme 487

Scheme 487
Scheme 487
  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.

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the front marking (nozzle diameter approximately 1.0 mm).

Scheme 488

Scheme 488
Scheme 488
CAUTIONThe lubrication system could be plugged with excess sealant. Do not apply sealant beads thicker than specified.

Apply an even and light bead of sealant in the clean groove on the guide frame.

Scheme 489

Scheme 489
Scheme 489

Note. The guide frame must be installed within 5 minutes after applying the sealant.

Tighten the guide frame bolts. (Scheme 430)

Check the camshaft "TDC" position

  1. It must be possible to insert the -T10252- as far as the stop.

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

Remove the -T10252-.

Drive the cover VALVETRAIN OVERVIEW in approximately 1 to 2 mm with the thrust piece 3334.

The rest of the installation is performed in reverse order of removal, noting the following

CAUTIONRisk of damaging valves and piston crowns. If camshafts are being rotated, crankshaft may not rest with any piston at "TDC". The engine must be no more than warm to touch.

Install the camshaft seal. Refer to EXHAUST CAMSHAFT SEAL .

Tighten the rear toothed belt guard. Refer to TOOTHED BELT DRIVE OVERVIEW .

Insert the fitting key in the camshaft and make sure it is seated correctly.

Installing camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

Install toothed belt (adjust timing) TOOTHED BELT DRIVE OVERVIEW .

VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

  1. Spark Plug Removal Tool 3122 B
  2. Valve Seal Removal Tool 3364
  3. Valve Stem Seal Driver 3365
  4. Valve Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for 2.0L FSI Engine VAS 5161/19B
  5. Adapter T40012

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.

Remove spark plugs with 3122 B.

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

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

Scheme 490

Scheme 490
Scheme 490

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

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

Scheme 491

Scheme 491
Scheme 491

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

Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

  1. Minimum pressure: 6 bar positive pressure.

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

Scheme 492

Scheme 492
Scheme 492

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 493

Scheme 493
Scheme 493

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 retainer.

Move the knurled bolt to the left and right.

  1. Valve retainers 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.

  1. Pressurized air hose remains connected.

Remove the valve spring and the valve spring plate.

Pull off valve stem seals with the 3364.

Scheme 494

Scheme 494
Scheme 494

If the 3364 cannot be used, on several valve stem seals due to restricted clearance, proceed as follows

Drive out the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

Scheme 495

Scheme 495
Scheme 495

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

Scheme 496

Scheme 496
Scheme 496

Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

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

CAUTIONRisk of damage when installing valve stem seals. Place plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

Scheme 497

Scheme 497
Scheme 497

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 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 498

Scheme 498
Scheme 498
  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 retainers are inserted in this manner.

Release pressure fork with knurled screw still raised.

Repeat the procedure on each valve.

Assembling

Assemble in reverse order of disassembling. Note the following

Install the camshafts. Refer to CAMSHAFTS .

Install spark plugs. Refer to SPARK PLUGS, REMOVING AND INSTALLING

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. Engine and Transmission Holder VAS 6095
  5. 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.

Insert the VAS 6419 in the VAS 6095.

Scheme 499

Scheme 499
Scheme 499

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 the guide plate for 2.0L FSI engine VAS 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 500

Scheme 500
Scheme 500

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

Scheme 501

Scheme 501
Scheme 501

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 502

Scheme 502
Scheme 502

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 retainer.

Move the knurled bolt to the left and right.

  1. Valve retainers 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.

CAUTIONRisk of damage when installing valve stem seals. Place plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve 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.

  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 retainers 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 .

Scheme 503

Scheme 503: SPECIAL TOOLS
Scheme 503: SPECIAL TOOLS

Special tools and workshop equipment required

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

Scheme 504

Scheme 504
Scheme 504

Special tools and workshop equipment required

  1. Seal Puller - General Useage 2085
  2. Retainer 3036
  3. Assembly Tool T10071
  4. Puller T40001
  5. M12 nut, quantity: 2

Scheme 505

Scheme 505
Scheme 505

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 Cotters Asm/Dis-Asm Device VAS 5161 with Guide Plate for 2.0L FSI Engine VAS 5161/19B
  5. Adapter T40012

Special tools and workshop equipment required

Scheme 506

Scheme 506
Scheme 506

Scheme 507

Scheme 507
Scheme 507

Scheme 508

Scheme 508
Scheme 508

Scheme 509

Scheme 509
Scheme 509

Scheme 510

Scheme 510
Scheme 510

Scheme 511

Scheme 511
Scheme 511

Scheme 512

Scheme 512
Scheme 512

Scheme 513

Scheme 513
Scheme 513

Scheme 514

Scheme 514
Scheme 514

Scheme 515

Scheme 515
Scheme 515

Scheme 516

Scheme 516
Scheme 516
  1. Spark Plug Removal Tool 3122 B
  2. Compression Tester V.A.G 1763
  3. Dial Gauge Holder VW 387
  4. Dial Gauge 0-10 mm VAS 6079
  5. Engine Support Bridge 10 - 222 A
  6. Shackle 10 - 222 A /12
  7. Adapter T40093/6 qty. 2
  8. Hose Clip Pliers V.A.G 1921
  9. Polydrive Bit and Drive Socket T10070
  10. Hose Clamps Up to 25 mm Dia. 3094
  11. Engine and Transmission Holder VAS 6095
  12. Not illustrated
  13. Cylinder Head Tensioning Device VAS 6419

See also:
• COOLANT PUMP
• COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW
• SEALING FLANGE, BELT PULLEY SIDE
• ENGINE AND TRANSMISSION MOUNTS OVERVIEW
• Removal and Installation
• SPARK PLUGS, REMOVING AND INSTALLING
• COOLING SYSTEM, DRAINING AND FILLING
• Removal and Installation
• RIBBED BELT TENSIONER
• VIBRATION DAMPER
• SUBFRAME MOUNT, ADJUSTING
• RIGHT FRONT COOLANT PIPE
• COOLANT PIPES OVERVIEW
• TURBOCHARGER OVERVIEW
• FAN SHROUD
• TURBOCHARGER
• CLEAN WORKING CONDITIONS
• Removal and Installation
• CHARGE AIR COOLER OVERVIEW
• Removal and Installation
• TOOTHED BELT
• INSTALLING (ADJUSTING VALVE TIMING)
• CAMSHAFT ADJUSTMENT VALVE 1
• EXHAUST CAMSHAFT SEAL
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED
• CAMSHAFTS
• CAMSHAFT, MEASURING AXIAL PLAY
• CAMSHAFT, MEASURING RADIAL PLAY
• CAMSHAFT ADJUSTER
• VALVE DIMENSIONS
• CYLINDER HEAD COVER
• VALVETRAIN OVERVIEW

More articles — Engine