2.0L - Cylinder Head, Valvetrain - Engine Code(s): Cdma (Coupe): Overview Audi TT 8J facelift

Scheme 422

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»(ref-505593-S02009278642012100100000)
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»(ref-505593-S20972033752012100100000)
15. Bolt 33 Nm
16. Damper Roller
17. Sealing Flange Removing and Installing, refer to «SEALING FLANGE, BELT PULLEY SIDE»(ref-505656-S35674243482012100100000)
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»(ref-505672-S40464983732012100100000) Installing (adjusting valve timing) «INSTALLING (ADJUSTING VALVE TIMING)»(ref-505672-S08864966262012100100000)
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»(ref-505670-S37778287422012100100000)

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

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»(ref-505672-S19649410362012100100000)
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»(ref-505672-S41552523922012100100000) (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»(ref-505672-S06605533962012100100000) Tightening specification and sequence (Scheme 426)

Scheme 425

Scheme 426

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

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

1. Minimum dimension -a- = 139.20 mm.

VALVETRAIN OVERVIEW

Scheme 429

1. Bolt Replace Loosen and tighten with retainer 3036 Tightening specifications «TOOTHED BELT DRIVE OVERVIEW»(ref-505672-S04251597212012100100000)
2. Toothed Belt Camshaft Gear
3. Shaft Seal For exhaust camshaft Removing and installing, refer to «EXHAUST CAMSHAFT SEAL»(ref-505672-S30010341462012100100000)
4. Cylinder Head
5. Valve Guide Checking, refer to «VALVE GUIDES, CHECKING»(ref-505672-S42035333002012100100000)
6. Valve Stem Seal Replace, refer to «VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED»(ref-505672-S41607951532012100100000), «VALVE STEM SEALS WITH CYLINDER HEAD REMOVED»(ref-505672-S05503635362012100100000)
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»(ref-505672-S04551358082012100100000) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(ref-505672-S38999604902012100100000) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(ref-505672-S23165951252012100100000) 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»(ref-505672-S39077899692012100100000)
16. Bolt Replace 20 Nm plus an additional 45° turn
17. Intake Camshaft Removing and installing, refer to «CAMSHAFTS»(ref-505672-S04551358082012100100000) Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(ref-505672-S38999604902012100100000) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(ref-505672-S23165951252012100100000) Maximum run out: 0.04 mm
18. Chain Tensioner Removing, refer to «CAMSHAFT ADJUSTER»(ref-505672-S39077899692012100100000) 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»(ref-505672-S24263596952012100100000)
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»(ref-505672-S35460790532012100100000) Valve Guides, Checking, refer to «VALVE GUIDES, CHECKING»(ref-505672-S42035333002012100100000)
24. Intake Valve Do not rework, only lapping is permitted For the correct valve dimensions, refer to «VALVE DIMENSIONS»(ref-505672-S35460790532012100100000) Valve guides, checking, refer to «VALVE GUIDES, CHECKING»(ref-505672-S42035333002012100100000)
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

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°.