Audi TT (2007 year). Manual — part 31
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Then turn the crankshaft in direction of engine rotation until the
pin -arrow- on the crankshaft stop engages in the sealing
flange as the crankshaft rotates.
– Install toothed belt (adjust valve timing)
.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install cylinder head cover
.
.
– Install exhaust gas recirculation pipes
.
– Install air pipe (left-side)
.
– Install gear selector cable and gate selector cable ⇒ Rep. Gr.
34 .
– Install particulate filter
.
– Install exhaust gas temperature sender 1 -G235-
– Install support for turbocharger
.
– Install air hose with plug-in connector
Gr. 27 .
– Change engine oil ⇒ Maintenance ; Booklet 810 .
– Fill cooling system with fresh coolant
2.5
Checking compression
To check compression, select function “Self-diagnosis compati‐
ble systems” in “Guided Fault Finding” ⇒ Vehicle diagnosis, test‐
ing and information system VAS 5051.
2. Cylinder head
115
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3
Valve gear
Caution
Avoid damage to valves and piston crowns after working on
valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
3.1
Valve gear - exploded view
1 - Oil seal
❑ Renewing
2 - Bolt
❑ Correct sequence when
❑ Tightening torque and
sequence
3 - Nut
❑ Correct sequence when
❑ Tightening torque and
sequence
4 - Retaining frame
❑ With integrated cam‐
shaft bearings
❑ Removing and installing
5 - Exhaust camshaft
❑ Removing and installing
❑ Measuring axial clear‐
ance
❑ Measuring radial clear‐
ance
6 - Inlet camshaft
❑ Removing and installing
❑ Measuring axial clear‐
ance
❑ Measuring radial clear‐
116
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
ance
7 - Roller rocker finger
⇒ “3.5 Removing and installing camshafts”, page 121
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surfaces before installing
8 - Hydraulic valve compensation element
❑ With retaining clip
❑ Mark installation position for re-installation
❑ Lubricate contact surfaces before installing
9 - Valve
❑ Must not be machined; only grinding-in is permissible
❑ Mark installation position for re-installation
❑ Checking
❑ Valve dimensions
10 - Cylinder head
11 - Valve stem oil seal
❑ Renewing: with cylinder head installed
12 - Valve spring
13 - Valve spring plate
14 - Valve cotters
15 - Sealing cap
❑ Renew
❑ Removing sealing cap with retaining frame installed: pierce on one side with an awl and pry out
❑ Installing: drive in without sealant using suitable thrust piece
❑ Installation depth 1 ... 2 mm
Retaining frame - tightening torque and sequence
– Tighten retaining frame bolts and nuts in the sequence
-1 ... 24- in 2 stages as follows:
1.
Screw in bolts and nuts evenly by hand until they make con‐
tact.
• The retaining frame should make contact with the cylinder
head over the full surface.
2.
Tighten to 10 Nm.
3.2
Measuring axial clearance of camshafts
Special tools and workshop equipment required
3. Valve gear
117
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge -VAS 6079-
Procedure
– Remove retaining frame
⇒ “3.5 Removing and installing camshafts”, page 121
– Secure dial gauge -VAS 6079- with universal dial gauge brack‐
et -VW 387- to cylinder head as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance on inlet camshaft and exhaust camshaft
• Specification: 0.048 … 0.118 mm.
• Wear limit: 0.17 mm.
3.3
Measuring radial clearance of cam‐
shafts
Special tools and workshop equipment required
♦ Plastigage
Procedure
– Remove roller rocker fingers
⇒ “3.5 Removing and installing camshafts”, page 121
– Clean bearing and bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Fit retaining frame and tighten to 10 Nm without rotating cam‐
118
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