Audi TT (2007 year). Instruction - page 33
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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.
Caution
Protect lubrication system and bearings against contamina‐
tion.
♦ Cover exposed parts of the engine.
WARNING
Protect eyes against injuries.
♦ Wear safety goggles.
– Remove remaining sealant from cylinder head and retaining
frame using rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.
– Oil running surfaces of both camshafts.
Set up camshaft fitting tool -T40094- as follows:
– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -
T40094/2- onto position -A-.
3. Valve gear
123
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.
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .
– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.
– Place exhaust camshaft in supports -T40094/9- and -
T40094/10- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft, until gear
teeth engage -arrows-.
– Fit retaining frame -1- on camshafts.
• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool -T40095- and fix camshafts in
position in retaining frame, as shown in illustration.
– Detach top section -T40094/11- .
124
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.
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2
mm).
Caution
Make sure excess sealant does not contaminate camshaft
bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant onto clean sealing surfaces of cylinder
head as shown in illustration.
• Thickness of sealant beads: 2 ... 3 mm.
Note
♦
The retaining frame should be fitted and secured without de‐
lay, as the sealant starts hardening immediately.
♦
After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Take camshafts together with retaining frame, camshaft fitting
tool -T40095- and clamping tool -T40096/1- out of camshaft
fitting tool -T40094- and insert components carefully into cyl‐
inder head.
3. Valve gear
125
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.
– Screw in retaining frame bolts and nuts in the sequence
-1 ... 24- evenly by hand until they make contact.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten bolts and nuts
⇒ page 117
.
– Remove camshaft fitting tool -T40095- and clamping tool -
T40096/1- .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install camshaft oil seal
⇒ page 119
.
– Drive new sealing cap
⇒ Item 15 (page 117)
into cylinder head
to a depth of approx. 1 ... 2 mm using suitable thrust piece.
⇒ page 98
.
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.
3.6
Checking hydraulic tappets
Note
♦
The hydraulic compensation elements cannot be serviced.
♦
Irregular valve noises when starting engine are normal.
Special tools and workshop equipment required
♦ Feeler gauge 0.20 mm
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If irregular valve noise disappears but repeatedly re-occurs when
travelling short distances, renew oil retention valve. The oil re‐
tention valve is located in the oil filter bracket
⇒ Item 3 (page 151)
.
– If the compensation elements are still noisy, locate the defec‐
tive compensation element as follows:
– Remove cylinder head cover
⇒ page 98
.
126