audi A3 (2006) ENGINE 2.0 Liter - General, Technical Data

ENGINE

2.0 Liter - General, Technical Data - Engine Code(s): BPY

00 GENERAL, TECHNICAL DATA

GENERAL INFORMATION

SAFETY PRECAUTIONS

Note the following when working on the fuel system:

-- Procedures before opening high pressure fuel injection system. Refer to General Information .

To prevent personal injury and damage to the injection and ignition system, observe the following:

l The ignition must be switched off before connecting or disconnecting injection and ignition system

wiring or tester cables.

l Only clean engine with ignition switched off.

l If electrical connectors were disconnected and the engine was started, then malfunctions have been stored

in the engine control modules.

-- Disconnect the battery. Refer to Removal and Installation .

Before Opening High Pressure Fuel Injection System

WARNING:

There is a risk of injury because the fuel is under very high pressure.

l Reduce the fuel pressure down to residual pressure before opening

high pressure area of the fuel injection system.

l To reduce remaining residual pressure, place a clean cloth around

the connector and carefully loosen connector.

CAUTION:

Danger of causing damage to electrical components when disconnecting the battery.

l Complete the steps for disconnecting the battery. l Turn off the ignition and disconnect the battery.

WARNING:

l The injection system is separated into a high-pressure section

(maximum approximately 120 bar) and a low-pressure section (approximately 6 bar).

l Before opening high pressure area, fuel pressure must be reduced

to a residual pressure of approximately 6 bar. Refer to General

2006 Audi A3

ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

2006 Audi A3

ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

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Note the following when working on the cooling system:

If it is necessary to use testing and measuring devices on road tests, observe the following:

Note the following when working on the exhaust system:

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. Observe the following guidelines for cleanliness when working on the fuel system, injection system and turbocharger:

l Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake

cleaner, and then cleaned area must be dried completely.

l Seal the open lines and connections immediately with clean plugs, for example, from the engine bung set

Information .

WARNING:

Risk of scalding due to hot steam and hot coolant.

l The cooling system is under pressure when the engine is warm. l Cover the coolant reservoir cap with a cloth and then open it slowly

to release the pressure in the system.

CAUTION:

The vehicle could overheat if the cap is installed incorrectly.

l The cap must engage noticeably when sealing.

WARNING:

Distraction and improperly secured test equipment can lead to accidents.

There is a risk that the passenger airbag could deploy in a collision.

l Operating testing and measuring equipment while driving creates a

distraction.

l There is an increased risk of injury due to unsecured testing and

measuring equipment.

l Always secure testers on the rear seat with a strap and have a

second person on the rear seat operate them.

CAUTION:

Danger of damaging the decoupling element.

l Decoupling element must not be bent more than 10°. l Do not load decoupling element on cable. l Do not damage wire mesh at decoupling element.

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ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

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VAS 6122.

l Place removed parts on a clean surface and cover them with lint-free cloths.

l Carefully cover over opened components or seal, if repairs are not performed immediately.

l Only install clean components: Only unpack replacement parts immediately prior to installation. Do not

use parts that have been stored out of their original packaging (for example in tool boxes etc.).

l If system is open, do not work with compressed air and do not move the vehicle.

l Make sure no fuel gets onto the fuel hoses. If necessary, wipe off the fuel hoses immediately.

l Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

ENGINE NUMBER

The engine number ("engine code" and "serial number") are located at the front of the engine/transmission joint.

In addition, a sticker with "engine code" and "serial number" is affixed to the toothed belt guard.

The engine code is also included on the vehicle data plates.

ENGINE CONTAMINANTS

l To prevent foreign objects from entering when working on the engine, seal open intake and exhaust

channels with suitable plugs, for example from the engine bung set VAS 6122.

CONTACT CORROSION

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only install connecting elements that are treated with a special coating.

Also, rubber or plastic parts and adhesive consist of non-conductive materials.

If there are doubts about the suitability of parts, generally use new parts.

LINES, ROUTING AND SECURING

l Mark the individual fuel, hydraulic and vacuum lines for the EVAP canister system as well as the

electrical wires before disconnecting and/or removing them. This will prevent a mix-up when reconnecting them. If necessary, draw sketches or take pictures.

l Due to the limited space inside the engine compartment, be especially careful when working near moving

or hot parts. This will also prevent damaging the lines.

NOTE:

Only original replacement parts are recommended, they are checked and compatible with aluminum.

Audi accessories are recommended.

Damage due to contact corrosion is not covered by warranty.

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ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

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COOLERS, CONDENSERS AND CHARGE AIR COOLERS

When assembled correctly, the radiator, condenser and turbocharger may have slight impressions on their fins. This is not damage. Do no replace the cooler, condenser or turbocharger because of impressions like that.

SPECIFICATIONS

ENGINE DATA

DIAGNOSIS AND TESTING

FUEL SYSTEM, CHECKING FOR LEAKS

-- Let the engine run a few minutes at a moderate speed.

-- Turn off the ignition.

-- Check the entire fuel system for leaks.

-- If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.

-- Then perform a road test and depress the accelerator pedal all the way at least one time.

-- Then check the high pressure area again for leaks.

VACUUM SYSTEM, CHECKING

Code Letters

AXX

BPY

BWA

Displacement

liter

1.984

Output

kW at RPM

147/5700

147/5100

Torque

Nm at RPM

280/2000

280/1800

Bore

diameter mm

82.5

Strokemm92.8

92.8

Compression ratio

10.5

10.3

RON

98 1)98 1)98

1)

Fuel injection and ignition system

FSI

Ignition sequence

1-3-4-2

Knock control

yes

Turbocharger

yes

Exhaust gas recirculation (EGR)

nonono

Variable intake manifold

nonono

Variable valve timing

yes

Secondary air injection (AIR)

nonono

l

1)

Unleaded RON 95 is also permissible, although with reduced power.

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ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

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Special tools and workshop equipment required

l Hand Vacuum Pump VAS 6213

Procedure

-- Check all vacuum lines in the vacuum system for:

l Cracks

l Damage caused by animals

l Crimps

l Leaks and leakage

-- Check the vacuum line leading to and from the solenoid valve.

-- If there is a fault, check the vacuum lines for the named component, but also all the vacuum lines.

-- If using the VAS 6213 does not produce any pressure or if the pressure drops again right away, then check the hand vacuum pump and the connection hoses for leaks.

SPECIAL TOOLS

Special tools and workshop equipment required

l Hand Vacuum Pump VAS 6213

Fig. 1: Hand Vacuum Pump VAS 6213 Courtesy of AUDI OF AMERICA, LLC

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ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

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ENGINE

2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

13 CRANKSHAFT, CYLINDER BLOCK

DESCRIPTION AND OPERATION

RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW

NOTE:

Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions. When installing, make sure the belt is correctly seated in the belt pulley.

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 1: Ribbed Belt And Assembly Bracket Overview Courtesy of AUDI OF AMERICA, LLC

1. Belt Pulley

l For the ribbed belt

l Removing and installing , refer to VIBRATION DAMPER

2. Special Bolt

l Replace

l 20 Nm plus an additional 90° turn

3. Bolt

l 23 Nm

4. Ribbed Belt Tensioning Damper

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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l To release tension on ribbed belt, pivot using open-end wrench.

l Secure tensioner with special tool locking pin T10060A

5. Bracket for Assemblies

l Removing and installing , refer to ACCESSORY ASSEMBLY BRACKET

6. Bolt

l 23 Nm

7. Bolt

l 23 Nm

8. Generator

l Removing and installing , refer to REMOVAL AND INSTALLATION

l Moving the threaded bushings on the generator slightly to the rear will make is easier to install the

generator.

9. Bolt

l Insert with locking fluid

l Locking fluid

l Follow the tightening sequence, refer to ACCESSORY ASSEMBLY BRACKET

10. Bushing

l 2 pieces

11. Bolt

l 25 Nm

12. Air Conditioner (A/C) Compressor

l Removing and installing . Refer to Removal and Installation

13. Ribbed Belt

l Ribbed belt routing, refer to Fig. 2

l Check for wear

l Do not kink

l Removing and installing , refer to RIBBED BELT

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 2: Identifying Ribbed Belt Routing Courtesy of AUDI OF AMERICA, LLC

Fig. 3: Removing/Installing Accessory Assembly Bracket Bolts Courtesy of AUDI OF AMERICA, LLC

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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-- Install bolts -1 through 6- and tighten by hand.

-- Tighten bolts -1 through 6- to 40 Nm.

FRONT SEALING FLANGE OVERVIEW

Fig. 4: Front Sealing Flange Assembly Overview Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l Replace

l 90 Nm plus an additional 90° turn

l Do not oil

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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l Fastening counter support 3415, refer to Fig. 6

2. Crankshaft Toothed Belt Sprocket

l There must be no oil on the contact surface between the toothed belt sprocket and crankshaft

l Only possible to install in one position

3. Bolt

l Tightening sequence, refer to Fig. 5

4. Seal

l Removing and installing , refer to CRANKSHAFT SEAL.

l Do not oil

5. Sealing Flange, Front

l Must sit on alignment pins

l Removing and installing , refer to FRONT SEALING FLANGE

6. Alignment Pins

7. Toothed Belt Gear Diamond Disc

l Replace after removing toothed belt gear

8. Bolt

l Tightening sequence , refer to Fig. 5

9. Cylinder Block

l Crankshaft, removing and installing , refer to CRANKSHAFT OVERVIEW

l Piston and connecting rod, disassembling and assembling, refer to PISTONS AND

CONNECTING ROD OVERVIEW

Fig. 5: Fastening Bolts In Specified Order Courtesy of AUDI OF AMERICA, LLC

-- Install bolts -1 to 10- and tighten by hand.

2006 Audi A3

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-- Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

-- Tighten bolts -7 to 10- to 15 Nm.

Fig. 6: Crankshaft Toothed Belt Sprocket, Removing And Installing Courtesy of AUDI OF AMERICA, LLC

REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW

NOTE:

Servicing clutch, refer to DESCRIPTION AND OPERATION .

2006 Audi A3

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Fig. 7: Rear Sealing Flange And Dual-Mass Flywheel Assembly Overview Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l Replace

l 60 Nm plus additional 90° turn

l For dual-mass flywheel/drive plate

2. Dual Mass Flywheel

l Dual mass flywheel, removing and installing, refer to DUAL MASS FLYWHEEL.

l Only possible to install in one position - Bores are offset

3. Intermediate Plate

l Must be located on dowel sleeves

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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l Be careful not to damage or bend when installing

l Is hooked in at sealing flange, refer to Fig. 9

4. Bolt

l Tightening sequence , refer to Fig. 8

5. Sealing Flange with Rear Seal

l Always replace as a complete unit

l To install, use provided guide sleeve

l Removing and installing , refer to REAR SEALING FLANGE

l Do not oil or grease the sealing lip of seal

l Wipe off any oil on the crankshaft bearing pin with a clean cloth before installing.

l Guide sleeve may only be removed after the sealing flange has been slid onto the crankshaft pin.

6. Fitting Pin

7. Bolt

l Tightening sequence , refer to Fig. 8

8. Cylinder Block

l Crankshaft, removing and installing, refer to CRANKSHAFT OVERVIEW

l Piston and connecting rod, disassembling and assembling, refer to PISTONS AND

CONNECTING ROD OVERVIEW

Fig. 8: Rear Sealing Flange Bolts Courtesy of AUDI OF AMERICA, LLC

-- Install bolts -1 to 8- and tighten by hand.

-- Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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-- Tighten bolts -7 to 8- to 15 Nm.

Fig. 9: Identifying Intermediate Plate Alignment Bushings Courtesy of AUDI OF AMERICA, LLC

-- Hook in intermediate plate at sealing flange and push it onto the alignment sleeves -arrows-.

CRANKSHAFT OVERVIEW

NOTE:

Secure engine to assembly stand using engine and transmission holder VAS 6095 when performing repair work. Refer to ENGINE, SECURING ON ASSEMBLY STAND .

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 10: Crankshaft Assembly Overview Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l 65 Nm plus an additional 90° turn

2. Bearing Cap

l Bearing cap 1: Belt pulley side

l Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another

3. Bolt

l Replace

l 10 Nm plus an additional 90° turn

l Replace sensor wheel every time bolts are loosened, refer to Fig. 11

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4. Needle Bearing

l For vehicles with manual transmission

l Pulling out and driving in, refer to NEEDLE BEARINGS FROM CRANKSHAFT

5. Sensor Wheel

l For engine speed (RPM) sensor -G28-

l Only possible to install in one position - Bores are offset

l Replace sensor wheel every time bolts are loosened

l Removing and installing , refer to Fig. 11

6. Crankshaft

l Axial play new: 0.07 to 0.23 mm; Wear limit: 0.30 mm

l Check radial clearance with Plastigage 0.017 to 0.037 mm, Wear limit: 0.15 mm

l Do not turn crankshaft when measuring radial play

l Crankshaft dimensions, refer to CRANKSHAFT DIMENSIONS

7. Thrust Washers

l For bearing 3

8. Bearing Shell for Cylinder Block

l With lubricating groove

l Do not interchange used bearing shells (mark)

l Classification for replacement part ordering, refer to NEEDLE BEARINGS FROM

CRANKSHAFT

9. Chain Sprocket

l For chain for oil pump

l Removing and installing , refer to CHAIN SPROCKET

10. Bearing Shell

l Without lubricating groove

l Do not interchange used bearing shells (mark)

l The crankshaft bearing shells in the bearing caps are only available as a replacement part with a

"yellow" color marking.

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ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 11: Identifying Attachment Points, Countersunk Screws, Crankshaft & Sensor Wheel Courtesy of AUDI OF AMERICA, LLC

-- Always replace sensor wheel -2- whenever bolts are removed -1-.

l Tightening specifications , refer to CRANKSHAFT OVERVIEW

NOTE:

After tightening a second time, the attachment point of the countersunk screws of the sensor wheel are so deformed that the screw heads lie on the crankshaft

-3- -arrows- and the sensor wheel is loose underneath the screws.

Installation of sensor wheel is only possible in one position - the bores are offset.

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ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 12: Identification Of Crankshaft Bearing Shells For Cylinder Block (Gradual Introduction) - Engine Codes AEG, AVH, AZG, BEV Courtesy of AUDI OF AMERICA, LLC

From the factory, the upper bearing shells are allocated to the cylinder block with the correct thickness. Colored spots serve to identify the bearing thicknesses.

The letters marked on the lower sealing surface of the cylinder block identify which bearing thickness must be installed in which location.

PISTONS AND CONNECTING ROD OVERVIEW

NOTE:

Arrow points in direction of travel.

G

=

Yellow

B

=

Blue

W

=

White

NOTE:

If color markings can no longer be read, use the blue bearing shell.

The lower crankshaft bearing shells are always shipped as replacement part with "yellow" color marking.

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Fig. 13: Identifying Piston And Connecting Rod, Assembly Overview Courtesy of AUDI OF AMERICA, LLC

1. Connecting Rod Bolt

l Replace

l 30 Nm plus an additional 90° turn

l Lubricate threads and contact surface

l Use old bolt to measure radial play

l Tighten to 30 Nm to measure radial play, do not turn further

2. Pressure Relief Valve

27 Nm

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l Opening pressure 1.6 to 1.9 bar

3. Oil Spray Jet

l For piston cooling

4. Connecting Rod Bearing Cap

l Pay attention to the installed position

l Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position

and only to the corresponding connecting rod.

l Affiliation to the cylinder mark -B-

l Installation position: Markings -A- point to belt pulley side

5. Bearing Shells

l Upper bearing shell with oil hole for piston pin lubrication

l Installed location, refer to Fig. 18

l Do not interchange used bearing shells (mark)

l Axial play new: 0.10 to 0.30 mm; Wear limit: 0.40 mm

l Measure radial clearance with Plastigage: New: 0.02 to 0.06 m; Wear limit: 0.09 mm. Do not turn

crankshaft when checking radial clearance

6. Connecting Rod

l Only replace as set

l Affiliation to the cylinder mark -B-

l Installation position: Markings -A- point to belt pulley side

l With oil hole for piston pin lubrication

7. Circlip

8. Piston Pin

l If difficult to move, heat piston to approximately 60 °C (140 °F)

l Removing and installing using a pilot drift VW 222 A

9. Piston

l Checking, refer to Fig. 16

l Mark installed position and cylinder allocation

l Arrow on piston face points toward belt pulley side

l Install with piston ring compressor

l For the correct piston and cylinder dimensions, refer to PISTON AND CYLINDER

DIMENSIONS

l Cylinder bore, checking, refer to Fig. 17

10. Piston Rings

l Offset gaps by 120°

l Use piston ring pliers for removing and installing

l "TOP" mark must face up toward piston crown

l Checking ring gap, refer to Fig. 14

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l Check piston ring groove clearance, refer to Fig. 15

Fig. 14: Checking Piston Ring Gap Courtesy of AUDI OF AMERICA, LLC

-- Push ring squarely from above down to approximately 15 mm from bottom end of cylinder. To do this use a piston without rings.

Piston Ring Dimensions in mm

New

Wear Limit

Compression ring

0.20 to 0.40

0.8

Oil scraping ring

0.25 to 0.55

0.8

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Fig. 15: Checking Piston Ring Gap Courtesy of AUDI OF AMERICA, LLC

-- Clean the ring groove of piston before checking.

Piston Ring Dimensions in mm

New

Wear Limit

Compression ring

0.035 to 0.075

0.15

Oil scraping ring

0.03 to 0.065

0.15

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Fig. 16: Checking Piston Courtesy of AUDI OF AMERICA, LLC

-- Measure pistons approximately 10 mm from bottom edge and at points offset by 90° to piston pin axis.

l Deviation from nominal size: Max. 0.04 mm.

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Fig. 17: Checking Cylinder Bores Courtesy of AUDI OF AMERICA, LLC

Special tools and workshop equipment required

l Internal dial gauge 50 to 100 mm.

l Inside Micrometer Set 18-100 mm US 1033/S

-- Measure diagonally at 3 positions transversely -A- and longitudinally -B-.

l Deviation from nominal size: Max. 0.08 mm.

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Fig. 18: Bearing Shells - Installed Positions Courtesy of AUDI OF AMERICA, LLC

Bearing shell -1- with connecting rod oil bore -arrow-.

Bearing shell -2- without connected rod cover oil bore.

-- Place bearing shells centrally into connecting rod and connecting rod cover.

Dimension -a- must be the same at left and right.

SPECIFICATIONS

CRANKSHAFT DIMENSIONS

(Dimensions in mm)

PISTON AND CYLINDER DIMENSIONS

Honing Dimension

Crankshaft Bearing Pin Diameter

Connecting Rod Bearing Pin

Diameter

-0.017

-0.022

Basic dimension

54.00

47.80

-0.037

-0.042

Honing Dimension

Piston Diameter

Cylinder Bore Diameter

Basic dimension

mm

82.465

1)

82.51

l

1)

Measurements without graphite coating (thickness = 0.02 mm). The graphite coating wears off.

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FASTENER TIGHTENING SPECIFICATIONS

Accessory Assembly Bracket Tightening Sequence

-- Install bolts -1 through 6- and tighten by hand.

Component

Bolt Size

Nm

Air Conditioner (A/C) Compressor

-

25

Bearing Cap

-

65 + 90°

Belt Pulley for the Ribbed Belt

1

-

20 + 90°

Connecting Rod Bolt

1

-

30 + 90°

Crankshaft Toothed Belt Sprocket

1

-

90 + 90°

Dual-Mass Flywheel/Drive Plate

1

-

60 + 90°

Generator

-

23

Pressure Relief Valve

-

27

Ribbed Belt Tensioning Damper

-

23

Sensor Wheel

1

-

10 + 90°

l

1

Replace

2006 Audi A3

ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): BPY

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Fig. 19: Removing/Installing Accessory Assembly Bracket Bolts Courtesy of AUDI OF AMERICA, LLC

-- Tighten bolts -1 through 6- to 40 Nm.

Tightening Sequence of Front Sealing Flange

-- 1. Install bolts -1 to 10- and tighten by hand.

Fig. 20: Fastening Bolts In Specified Order Courtesy of AUDI OF AMERICA, LLC

-- 2. Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

-- 3. Tighten bolts -7 to 10- to 15 Nm.

Rear Tightening Sequence

-- 1. Install bolts -1 to 8- and tighten by hand.

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Fig. 21: Rear Sealing Flange Bolts Courtesy of AUDI OF AMERICA, LLC

-- 2. Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

-- 3. Tighten bolts -7 to 8- to 15 Nm.

DIAGNOSIS AND TESTING

CRANKSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

l Dial Gauge Holder VW 387

l Dial Gauge 0-10 mm VAS 6079

Procedure

-- Attach the VAS 6079 together with VW 387 to cylinder block and set indicator against crankshaft counterweight.

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Fig. 22: Attaching Dial Indicator Together With VW387 Dial Gauge Holder To Cylinder Block And Set Indicator Against Crankshaft Counterweight Courtesy of AUDI OF AMERICA, LLC

-- Press crankshaft by hand against gauge and set gauge to "0".

-- Press crankshaft off gauge and read value.

Axial clearance:

l New: 0.07 to 0.23 mm.

l Wear limit: 0.30 mm.

CRANKSHAFT, MEASURING RADIAL PLAY

Special tools and workshop equipment required

l Plastigage

Procedure

-- Remove main bearing cap and clean bearing cap and pins.

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

l Plastigage must rest in center of bearing shell.

NOTE:

Do not interchange used bearings

Bearing shells that are worn down to the nickel layer must be replaced.

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-- Position the main bearing cap and tighten it to 65 Nm. Do not rotate the crankshaft when doing so.

-- Remove main bearing caps again.

-- Compare width of Plastigage with measuring scale.

Radial Clearance:

l New: 0.017 to 0.037 mm

l Wear limit: 0.15 mm

REMOVAL AND INSTALLATION

RIBBED BELT

Special tools and workshop equipment required

l Locking Pin T10060A

l Spring Type Clip Pliers VAS 5024 A

Removing

-- Remove the engine cover and air filter. Refer to Removal and Installation .

-- Pull the EVAP canister with connected lines upward -arrow- out of the retainer and lay it aside.

Fig. 23: Identifying EVAP Canister Courtesy of AUDI OF AMERICA, LLC

NOTE:

Before removing the ribbed belt, mark the turning direction on it with chalk or a

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-- Mark the rotation direction on the ribbed belt.

-- Pivot the ribbed belt tensioner in direction of -arrow- to relieve tension on the ribbed belt.

Fig. 24: Identifying Method To Relieve Tension On Poly V-Belt Courtesy of AUDI OF AMERICA, LLC

-- Secure tensioning element using the T10060A.

felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

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Fig. 25: Identifying Lock Tensioner With Locking Pin T10060 A Courtesy of AUDI OF AMERICA, LLC

-- Remove the ribbed belt.

Installing

Install in reverse order of removal. Note the following:

-- Place ribbed belt onto belt pulleys of crankshaft and A/C compressor.

NOTE:

Make sure, before installing ribbed belt, that all ancillaries (generator and A/C compressor) are secured tightly.

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Fig. 26: Identifying Ribbed Belt Routing Courtesy of AUDI OF AMERICA, LLC

-- Place ribbed belt onto generator belt pulley lastly, and release tensioner.

-- Check ribbed belt for correct positioning.

-- Start the engine and check the belt running.

ACCESSORY ASSEMBLY BRACKET

Special tools and workshop equipment required

l Locking Pin T10060A

l Spring Type Clip Pliers VAS 5024 A

Removing

-- Remove the engine cover and air filter. Refer to Removal and Installation .

-- Remove cover from above the battery, by pressing the release buttons -arrows-.

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Fig. 27: Battery Cover Courtesy of AUDI OF AMERICA, LLC

-- With ignition switched off, disconnect battery ground (GND) cable -arrow-.

Fig. 28: Battery Ground Strap Courtesy of AUDI OF AMERICA, LLC

-- Pull the EVAP canister with connected lines upward -arrow- out of the retainer and lay it aside.

WARNING:

Follow the steps for disconnecting the battery. Refer to REMOVAL AND INSTALLATION .

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Fig. 29: Identifying EVAP Canister Courtesy of AUDI OF AMERICA, LLC

-- Pivot the ribbed belt tensioner in direction of -arrow- to relieve tension on the ribbed belt.

Fig. 30: Identifying Method To Relieve Tension On Poly V-Belt Courtesy of AUDI OF AMERICA, LLC

-- Secure tensioning element using the T10060A.

NOTE:

Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

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Fig. 31: Identifying Lock Tensioner With Locking Pin T10060 A Courtesy of AUDI OF AMERICA, LLC

-- Remove ribbed belt.

-- Remove ribbed belt tensioner -arrows-.

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Fig. 32: Ribbed Belt Tensioner Bolts Courtesy of AUDI OF AMERICA, LLC

-- Discharge the refrigerant circuit. Refer to Description and Operation .

-- Remove the generator. Refer to REMOVAL AND INSTALLATION

-- Remove noise insulation. Refer to Removal and Installation .

-- Remove right noise insulation fasteners -1 to 3-.

Fig. 33: Identifying Fasteners Courtesy of AUDI OF AMERICA, LLC

-- Remove the A/C compressor. Refer to Removal and Installation

-- Remove the accessory assembly bracket - bolts -1 to 6-.

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Fig. 34: Removing/Installing Accessory Assembly Bracket Bolts Courtesy of AUDI OF AMERICA, LLC

Installing

Installation is in the reverse order of removal, noting the following.

l For the correct tightening specifications, refer to RIBBED BELT AND ASSEMBLY BRACKET

OVERVIEW

-- Tighten the bolts in the sequence -1 to 6-.

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Fig. 35: Removing/Installing Accessory Assembly Bracket Bolts Courtesy of AUDI OF AMERICA, LLC

-- Install the generator. Refer to REMOVAL AND INSTALLATION

-- Install A/C compressor. Refer to Removal and Installation .

-- Install the ribbed belt. Refer to RIBBED BELT.

-- Connect the battery. Refer to REMOVAL AND INSTALLATION .

VIBRATION DAMPER

Removing

l Ribbed belt removed. Refer to RIBBED BELT.

-- Remove the center noise insulation -1 to 3-.

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Fig. 36: Center Noise Insulation Bolts Courtesy of AUDI OF AMERICA, LLC

-- Remove right noise insulation fasteners -1 to 3-.

Fig. 37: Identifying Fasteners Courtesy of AUDI OF AMERICA, LLC

-- Remove vibration damper/belt pulley.

NOTE:

To loosen and tighten the crankshaft belt pulley, counter-hold at the center bolt using a offset box wrench.

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Installing

Install in reverse order of removal. Note the following:

l For the correct tightening specifications, refer to RIBBED BELT AND ASSEMBLY BRACKET

OVERVIEW

-- Install the crankshaft belt pulley using only original equipment bolts

Fig. 39: Installing Crankshaft Belt Pulley With Original Bolts Courtesy of AUDI OF AMERICA, LLC

Fig. 38: Identifying Vibration Damper/Belt Pulley Courtesy of AUDI OF AMERICA, LLC

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l Only possible to install in one position: The hole -arrow- in the crankshaft belt pulley must be positioned

over the raised area on the toothed belt sprocket

CRANKSHAFT SEAL

Special tools and workshop equipment required

l Seal Remover 3203

l Counter Support 3415

l Assembly Tool T10053

l Torque Wrench 5-50 Nm V.A.G 1331

l Torque Wrench 40-200 Nm V.A.G 1332

Removing

-- Remove ribbed belt. Refer to RIBBED BELT.

-- Toothed belt, removing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD or TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

-- Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with the 3415.

Fig. 40: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415 Courtesy of AUDI OF AMERICA, LLC

-- Remove the crankshaft-toothed belt sprocket center bolt -1- and remove the toothed belt sprocket -2-.

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Fig. 41: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc Courtesy of AUDI OF AMERICA, LLC

-- Remove diamond disc -3- from toothed belt gear.

-- To guide seal puller, thread center bolt into crankshaft by hand until stop.

-- Unscrew inner part of the 3203 nine rotations (approximately 20 mm) from outer part and secure with knurled-head screw.

-- Lubricate threaded head of 3203, position and forcefully screw into seal as far as possible.

Fig. 42: Exerting Firm Pressure To Oil Seal Extractor 3203 Into Oil Seal Courtesy of AUDI OF AMERICA, LLC

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-- Loosen knurled screw and turn inner portion against crankshaft until the seal is pulled out.

-- Secure the seal remover in a vise at the flat spots. Remove seal using pliers.

Installing

l For the correct tightening specifications, refer to FRONT SEALING FLANGE OVERVIEW

-- Clean running and sealing surface.

-- Before installing, remove oil remains from end of crankshaft with a clean cloth.

-- Position guide sleeve T10053/1 of the T10053 on the end of crankshaft.

Fig. 43: Fitting Guide Sleeve T10053/1 Onto Crankshaft Journal Courtesy of AUDI OF AMERICA, LLC

-- Slide seal over guide sleeve onto the crankshaft pin.

-- Press in the seal using center bolt of the toothed belt sprocket and pressure sleeve of the T10053 until it is flush.

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Fig. 44: Identifying Press Sleeve T10053 & Bolt Mounted Courtesy of AUDI OF AMERICA, LLC

-- Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-.

Fig. 45: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc Courtesy of AUDI OF AMERICA, LLC

-- Use the 3415 to tighten crankshaft toothed belt gear.

NOTE:

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

Do not oil the bolt for crankshaft toothed belt sprocket.

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Fig. 46: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415 Courtesy of AUDI OF AMERICA, LLC

-- Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

-- Install the ribbed belt. Refer to RIBBED BELT.

FRONT SEALING FLANGE

Special tools and workshop equipment required

l Counter Support 3415

l Assembly Tool T10053

l Torque Wrench 5-50 Nm V.A.G 1331

l Torque Wrench 40-200 Nm V.A.G 1332

l Hand drill with plastic brush attachment

l Protective eyewear

l Sealant

Removing

-- Remove ribbed belt. Refer to RIBBED BELT.

-- Remove toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD or TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

-- Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with 3415.

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Fig. 47: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415 Courtesy of AUDI OF AMERICA, LLC

-- Remove the crankshaft-toothed belt sprocket center bolt -1- and remove the toothed belt sprocket -2-.

Fig. 48: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc Courtesy of AUDI OF AMERICA, LLC

-- Remove diamond disc -3- from toothed belt gear.

-- Remove the bolts -1 through 10-.

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Fig. 49: Fastening Bolts In Specified Order Courtesy of AUDI OF AMERICA, LLC

-- Pry off and remove front sealing flange.

-- Drive out the seal from the removed flange.

Installing

l Tightening specifications , refer to FRONT SEALING FLANGE OVERVIEW

-- Carefully remove any sealant residue from the cylinder block and oil pan.

-- Remove sealant residue from sealing flange for example with a rotating plastic brush.

NOTE:

Place a rag over open part of oil pan.

WARNING:

Wear safety glasses.

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Fig. 50: Identifying Rotating Plastic Brush Courtesy of AUDI OF AMERICA, LLC

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

-- Cut tube nozzle at front marking (nozzle diameter: approximately 2 mm).

Fig. 51: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm) Courtesy of AUDI OF AMERICA, LLC

-- Apply a thin bead of sealant to the edge between cylinder block and oil pan -arrow-.

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Fig. 52: Applying Thin Bead Of Sealant To Edge Between Cylinder Block And Oil Pan Courtesy of AUDI OF AMERICA, LLC

-- Apply a thin bead of sealant -arrow- to the clean sealing surface of the sealing flange, as shown in the illustration.

Fig. 53: Applying Silicone Sealant Bead To Clean Sealing Surface Of Sealing Flange Courtesy of AUDI OF AMERICA, LLC

l Thickness of sealant bead: 2 to 3 mm.

CAUTION:

Risk of plugging oil pump strainer with excess sealant.

l Do not apply sealant bead thicker than indicated.

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-- Lightly coat the lower sealing surface of the sealing flange with sealant -shaded area-.

Fig. 54: Lightly Coating Lower Sealing Surface Of Sealing Flange With Sealant Courtesy of AUDI OF AMERICA, LLC

-- Carefully slide sealing flange onto reamed bolt at cylinder block.

-- Tighten sealing flange bolts in 3 stages as follows:

NOTE:

The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

NOTE:

The sealing flange must be installed within 5 minutes of being applied with sealant.

NOTE:

To install the sealing flange with installed seal, use the guide sleeve T10053/1.

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Fig. 55: Fastening Bolts In Specified Order Courtesy of AUDI OF AMERICA, LLC

-- Install bolts -1 through 10- and tighten by hand.

-- Tighten bolts -1 to 6- in a diagonal sequence in stages.

-- Tighten bolts -7 through 10-.

-- Install the crankshaft seal belt pulley side CRANKSHAFT SEAL.

-- Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-.

Fig. 56: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

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Courtesy of AUDI OF AMERICA, LLC

-- Use the 3415 to tighten crankshaft toothed belt gear.

Fig. 57: Crankshaft Toothed Belt Sprocket, Removing And Installing Courtesy of AUDI OF AMERICA, LLC

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

-- Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD or TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

-- Install the crankshaft belt pulley. Refer to VIBRATION DAMPER.

-- Install the ribbed belt. Refer to RIBBED BELT.

DUAL MASS FLYWHEEL

Special tools and workshop equipment required

l Flywheel Retainer 3067

Removing

NOTE:

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

Do not oil the bolt for crankshaft toothed belt sprocket.

NOTE:

The threads and shoulder must be free of oil and grease.

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l Transmission and clutch removed

-- Mark the dual-mass flywheel to the engine.

-- Rotate the dual-mass flywheel -A- so that the bolts -B- stand centered to the holes -arrows-.

Fig. 58: Identifying Dual-Mass Flywheel & Bolts Courtesy of AUDI OF AMERICA, LLC

-- When removing bolts -B-, make sure the bolt head does not come into contact with the dual-mass flywheel arrows- or the flywheel could be damaged when turning the bolt.

-- Insert 3067 into the hole in cylinder block -B-.

CAUTION:

To prevent damage to the dual-mass flywheel when removing, bolts -Bmust not be removed using an air-powered or impact wrench. Only removing bolts by hand is permitted.

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Fig. 59: Identifying Retainer -3067- Inserted In Hole On Cylinder Block Courtesy of AUDI OF AMERICA, LLC

-- Remove the dual-mass flywheel.

Installing

Install in reverse order of removal. Note the following:

l Tightening specifications , refer to REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL

OVERVIEW

-- Secure with new bolts.

-- Insert the 3067 into hole in cylinder block -A-.

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Fig. 60: Identifying Retainer -3067- Inserted In Hole On Cylinder Block Courtesy of AUDI OF AMERICA, LLC

REAR SEALING FLANGE

Special tools and workshop equipment required

l Hand drill with plastic brush attachment

l Protective eyewear

l Sealant

Removing

l Transmission removed

-- Remove the dual-mass flywheel. Refer to DUAL MASS FLYWHEEL.

-- Unhook the intermediate plate at sealing flange and at the alignment sleeves -arrows-.

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Fig. 61: Identifying Intermediate Plate Alignment Bushings Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 through 8-.

Fig. 62: Rear Sealing Flange Bolts Courtesy of AUDI OF AMERICA, LLC

-- Pull off the rear sealing flange.

Installing

l For the correct tightening specifications, refer to REAR SEALING FLANGE AND DUAL-MASS

FLYWHEEL OVERVIEW.

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-- Carefully remove any sealant residue from the cylinder block and oil pan.

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

-- Cut the tube nozzle at front marking (nozzle diameter: approximately 2 mm).

Fig. 63: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm) Courtesy of AUDI OF AMERICA, LLC

-- Apply a thin bead of sealant -arrow- to the edge between cylinder block and oil pan.

Fig. 64: Sealant Applied To Edge Between Cylinder Block And Oil Pan

NOTE:

Place a rag over open part of oil pan.

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Courtesy of AUDI OF AMERICA, LLC

-- Lightly coat the lower sealing surface of the sealing flange with sealant -shaded area-.

Fig. 65: Sealing Flange Sealing Surface Courtesy of AUDI OF AMERICA, LLC

-- To install, push the sealing flange -2- together with the guide sleeve -1- (included with replacement part) onto the crankshaft.

CAUTION:

Risk of plugging oil pump strainer with excess sealant.

l Do not apply sealant bead thicker than indicated.

NOTE:

The sealing flange must be installed within 5 minutes of being applied with sealant.

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Fig. 66: Sealing Flange And Guide Sleeve Courtesy of AUDI OF AMERICA, LLC

-- Then carefully push the sealing flange onto the locating pins on the cylinder block.

-- Fasten the bolts in the specified order:

-- Install bolts -1 through 8- and tighten by hand.

Fig. 67: Rear Sealing Flange Bolts Courtesy of AUDI OF AMERICA, LLC

-- Tighten bolts -1 through 6- in a diagonal sequence in stages.

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-- Tighten bolts -7 and 8-.

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

-- Hook in intermediate plate at sealing flange and push it onto the alignment sleeves -arrows-.

Fig. 68: Identifying Intermediate Plate Alignment Bushings Courtesy of AUDI OF AMERICA, LLC

-- Install dual-mass flywheel. Refer to DUAL MASS FLYWHEEL.

NEEDLE BEARINGS FROM CRANKSHAFT

Special tools and workshop equipment required

l Puller T10055

l With Adapter T10055/3

l Centering Mandrel 3176

l or Drift VW 207 C.

l Puller for example Kukko 21/2.

Removing

-- Pull out using standard extractor for example Kukko 21/2 -arrow-, T10055/3 and T10055.

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Fig. 69: Identifying Standard Extractor E.G. Kukko 21/2, Adapter T10055/3 And Puller T10055 Courtesy of AUDI OF AMERICA, LLC

Installing

-- Drive in using the VW 207 C or 3176.

Fig. 70: Driving In Needle Bearing Using Drift VW 207 C Courtesy of AUDI OF AMERICA, LLC

Installation depth dimension -a- = 2 mm

NOTE:

Side of needle bearing with writing on it must be readable when installed.

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Fig. 71: Identifying Installation Depth Dimension Courtesy of AUDI OF AMERICA, LLC

CHAIN SPROCKET

Special tools and workshop equipment required

l Press Tube 30 - 100

l Thrust Piece 40 - 105

l Two-arm puller, commercially available

l Protective gloves

Removing

-- Remove oil pan with oil pump. Refer to OIL PAN .

-- Remove front sealing flange. Refer to FRONT SEALING FLANGE.

-- Pull off crankshaft chain sprocket with claw puller -2- for example Kukko 44-1, while protecting end of crankshaft with the 40 - 105.

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Fig. 72: Pulling Off Chain Sprocket From Crankshaft Courtesy of AUDI OF AMERICA, LLC

Installing

Install in reverse order of removal. Note the following:

-- Heat up the chain sprocket in an oven for approximately 15 minutes at 220 °C (428 °F).

-- Using pliers, install chain sprocket on crankshaft end and slide onto crankshaft to stop using the 30 - 100.

WARNING:

Wear protective gloves!

NOTE:

Installation position: Wider shoulder of chain sprocket faces toward engine.

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Fig. 73: Installing Chain Sprocket Onto Crankshaft Up To Limit Stop Using Press Tube 30-100 Courtesy of AUDI OF AMERICA, LLC

-- Install oil pan with oil pump. Refer to OIL PAN .

SPECIAL TOOLS

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Fig. 74: Identifying Special Tools - Crankshaft Oil Seal - Belt Pulley End, Replacing (For PTFE Seals) Courtesy of AUDI OF AMERICA, LLC

Special tools and workshop equipment required

l Seal Remover 3203

l Counter Support 3415

l Assembly Tool T10053

l Torque Wrench 5-50 Nm V.A.G 1331

l Torque Wrench 40-200 Nm V.A.G 1332

Special tools and workshop equipment required

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l Dial Gauge Holder VW 387

Fig. 75: Dial Gauge Holder VW 387 Courtesy of AUDI OF AMERICA, LLC

l Dial Gauge 0-10 mm VAS 6079

Fig. 76: Dial Gauge VAS 6079 Courtesy of AUDI OF AMERICA, LLC

l Locking Pin T10060A

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Fig. 77: Identifying Locking Pin T10060 A Courtesy of AUDI OF AMERICA, LLC

l Spring Type Clip Pliers VAS 5024 A

Fig. 78: Identifying Spring Clamps VAS 5024A Courtesy of AUDI OF AMERICA, LLC

l Flywheel Retainer 3067

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Fig. 79: 3067 Counter-Hold Tool Courtesy of AUDI OF AMERICA, LLC

l Puller T10055

Fig. 80: Identifying Puller T10055 Courtesy of AUDI OF AMERICA, LLC

l With Adapter T10055/3

l Centering Mandrel 3176

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Fig. 81: 3176 Centering Mandrel Courtesy of AUDI OF AMERICA, LLC

l Press Tube 30 - 100

Fig. 82: Press Tube 30 - 100 Courtesy of AUDI OF AMERICA, LLC

l Thrust Piece 40 - 105

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Fig. 83: Identifying Thrust Piece 40-105 Courtesy of AUDI OF AMERICA, LLC

l Not illustrated:

l Drift VW 207 C

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Page 67

ENGINE

2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

15 CYLINDER HEAD, VALVETRAIN

DESCRIPTION AND OPERATION

TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW

Before removing the ribbed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.

NOTE:

Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover 25 and guard is divided in engine bracket area. Vehicles with divided toothed belt guard - assembly overview. Refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD.

2006 Audi A3

ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

2006 Audi A3

ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

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Page 1

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Page 1

Fig. 1: Toothed Belt Drive, Without Divided Toothed Belt Guard Overview Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l 10 Nm

l Insert with locking fluid

l Locking fluid

2. Upper Toothed Belt Guard

3. Bolt

l Replace

l 50 Nm plus an additional 180° turn

l Use retainer 3036 for loosening and tightening, refer to Fig. 2

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4. Camshaft Sprocket

l When removing and installing, remove toothed belt, refer to TOOTHED BELT, WITHOUT

DIVIDED TOOTHED BELT GUARD

l Installed position is fixed by woodruff key, refer to 7

l Camshaft sprocket, removing, refer to Fig. 3

5. Bolt

l 10 Nm

l Insert with locking fluid

l Locking fluid

6. Rear Toothed Belt Guard

7. Woodruff Key

l Make sure it is secure

8. Nut

l 25 Nm

9. Semi-Automatic Tensioning Roller

10. Coolant Pump

l Removing and installing , refer to COOLANT PUMP

11. O-ring

l Replace

l Coat with coolant

12. Bolt

l 25 Nm

13. Damper Roller

14. Bolt

l 15 Nm

15. Bolt

l 35 Nm

16. Damper Roller

17. Sealing Flange

l Removing and installing, refer to FRONT SEALING FLANGE

18. Toothed Belt Gear Diamond Disc

l Replace after removing toothed belt gear

19. Crankshaft Toothed Belt Sprocket

l There must be no oil on the contact surface between the toothed belt sprocket and crankshaft

l Only possible to install in one position

20. Bolt

l Replace

l 90 Nm plus an additional 90° turn

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l Do not oil

l Fastening counter support 3415, refer to Fig. 4

21. Toothed Belt

l Before removing, mark direction of rotation using chalk or felt-tip marker

l Check for wear

l Removing , refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD

l Installing (adjusting valve timing), refer to TOOTHED BELT, WITHOUT DIVIDED

TOOTHED BELT GUARD

22. Lower Toothed Belt Guard

23. Engine Support

l Removing : Toothed belt, removing and installing, refer to TOOTHED BELT, WITHOUT

DIVIDED TOOTHED BELT GUARD

24. Bolt

l 40 Nm

l Follow the tightening sequence Fig. 47

25. Cover for Toothed Belt Guard

Fig. 2: Loosening Bolt For Camshaft Sprocket Using Retainer 3036 Courtesy of AUDI OF AMERICA, LLC

-- When loosening and tightening the center bolt, use retainer 3036.

2006 Audi A3

ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

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Page 4

Fig. 3: Identifying Puller T40001, Claw T40001/6 And Claw T40001/7 Courtesy of AUDI OF AMERICA, LLC

-- Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

Fig. 4: Crankshaft Toothed Belt Sprocket, Removing And Installing Courtesy of AUDI OF AMERICA, LLC

-- When loosening and tightening the center bolt, use counter support 3415.

TOOTHED BELT DRIVE, WITH DIVIDED TOOTHED BELT GUARD OVERVIEW

NOTE:

Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover 25 and guard is divided in engine

2006 Audi A3

ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

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Page 5

Fig. 5: Toothed Belt Drive, With Divided Toothed Belt Guard Overview Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l 10 Nm

2. Upper Toothed Belt Guard

3. Bolt

l 50 Nm plus an additional 180°

l Use retainer 3036 for loosening and tightening, refer to Fig. 6

bracket area. Vehicles without divided toothed belt guard - assembly overview. Refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW.

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4. Camshaft Sprocket

l Installation position secured by woodruff key 7

l Camshaft sprocket, removing, refer to Fig. 7

5. Bolt

l 10 Nm

l Insert with locking fluid

6. Rear Toothed Belt Guard

7. Woodruff Key

l Make sure it is secure

8. Bolt

l 25 Nm

9. Semi-Automatic Tensioning Roller

10. Coolant Pump

l Removing and installing , refer to COOLANT PUMP

11. O-ring

l Replace

12. Bolt

l 25 Nm

13. Damper Roller

14. Bolt

l 15 Nm

15. Bolt

l 35 Nm

16. Damper Roller

17. Sealing Flange

l Removing and installing , refer to FRONT SEALING FLANGE

18. Diamond Disc

l Replace

19. Crankshaft Toothed Belt Sprocket

l There must be no oil on the contact surface between toothed belt gear, diamond disc and crankshaft

l Only possible to install in one position

20. Bolt

l Replace

l 90 Nm plus an additional 90° turn

l Do not oil

l Use counter support 3415 for loosening and tightening, refer to Fig. 8

21. Toothed Belt

l Before removing, mark direction of rotation using chalk or felt-tip marker

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l Check for wear

l Removing and installing , refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT

GUARD

22. Lower Toothed Belt Guard

23. Bolts

l 8 Nm

l 7 pieces

l For lower toothed belt guard

24. Engine Mount

25. Bolt

l 45 Nm

Fig. 6: Loosening Bolt For Camshaft Sprocket Using Retainer 3036 Courtesy of AUDI OF AMERICA, LLC

-- When loosening and tightening the center bolt, use retainer 3036.

2006 Audi A3

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Fig. 7: Identifying Puller T40001, Claw T40001/6 And Claw T40001/7 Courtesy of AUDI OF AMERICA, LLC

-- Pulling off camshaft sprocket with puller T40001 and claws T40001/6 and T40001/7.

Fig. 8: Crankshaft Toothed Belt Sprocket, Removing And Installing Courtesy of AUDI OF AMERICA, LLC

-- When loosening and tightening the center bolt, use retainer 3415.

CYLINDER HEAD OVERVIEW

NOTE:

Replace the cylinder head bolts.

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Fig. 9: Cylinder Head Assembly Overview

Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings.

When installing a replacement cylinder head with camshafts installed, contact surfaces between roller rocker lever and cam running surfaces must be oiled.

The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head.

When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

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Courtesy of AUDI OF AMERICA, LLC

1. Bolt

l Tightening sequence, refer to Fig. 10

2. Cylinder Head Cover

3. Gasket

l Replace if damaged or leaking

4. Valve Housing

5. Oil Filler Cap

6. Gasket

l Replace if damaged or leaking

7. Bolt

l 4 Nm

8. Cylinder Head Cover Gasket

l Replace if damaged or leaking

9. Vacuum Pump

10. Bolt

l 4 Nm

11. Camshaft Adjustment Valve 1 -N205-

l Removing , refer to CAMSHAFT ADJUSTMENT VALVE 1

12. Seal

l Replace

13. Bolt

l 10 Nm

14. Cable Bracket

15. Seal

l Replace if damaged or leaking

16. Bolt

l 10 Nm

17. Housing

18. Gasket

l Replace

19. Transport Strap

20. Bolt

l 25 Nm

21. Intake Manifold Stud Bolt

l 10 Nm

22. Partition Plate

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ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

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23. Cylinder Head Gasket

l Replace

l Note installation position: The part number faces the cylinder head

24. Bolt

l 10 Nm

25. Camshaft Position Sensor -G40-

26. Seal

27. Tensioning Roller Stud Bolt

l 10 Nm

28. Exhaust Manifold Stud Bolt

l 20 Nm

29. Cylinder Head

l Check for distortion, refer to Fig. 13

30. Cylinder Head Bolt

l Replace

l Tightening specification: 40 Nm plus an additional 180° turn

l Observe sequence for loosening, refer to Fig. 11

l Observe sequence for tightening, refer to Fig. 12

Fig. 10: Identifying Cylinder Head Cover Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- Install bolts -1 through 14- and tighten by hand.

-- Tighten the bolts -1 through 14- diagonally to 10 Nm.

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ENGINE 2.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): BPY

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Fig. 11: Cylinder Head Bolt Loosening Sequence Courtesy of AUDI OF AMERICA, LLC

-- Loosen cylinder head bolts in sequence shown and remove.

Fig. 12: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- Tighten cylinder head bolts in -1 through 10- sequence as follows

-- 1. Tighten to 40 Nm using a torque wrench.

-- 2. Tighten further 90° using a rigid wrench.

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-- 3. Tighten further 90° using a rigid wrench.

Fig. 13: Checking Cylinder Head For Distortion Courtesy of AUDI OF AMERICA, LLC

-- Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.

l Maximum permissible distortion: 0.05 mm.

VALVETRAIN OVERVIEW

NOTE:

The cylinder head and guide frame must be replaced together.

Do not start the engine for approximately 30 minutes after installing the camshafts. 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.

Always replace the gaskets and seals.

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Fig. 14: Valvetrain Overview Courtesy of AUDI OF AMERICA, LLC

1. 1 - Bolt

l Replace

l 50 Nm plus an additional 180° turn

l Use retainer 3036 for loosening and tightening, refer to Fig. 2

2. 2 - Camshaft Sprocket

3. 3 - Seal

l Removing and installing , refer to EXHAUST CAMSHAFT SEAL

4. 4 - Cylinder Head

l Reworking dimension, refer to Fig. 15

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5. 5 - Valve Guide

l Checking, refer to VALVE GUIDES, CHECKING

6. 6 - Valve Stem Seal

7. 7 - Valve Spring

8. 8 - Top Valve Spring Retainer

l Replace, refer to VALVE STEM SEALS, CYLINDER HEAD INSTALLED or VALVE STEM

SEALS WITH CYLINDER HEAD REMOVED

9. 9 - Valve Retainers

10. 10 - Hydraulic Valve Play Balancing Element

l Do not interchange

l Lubricate contact surface

11. 11 - Fitted Key

l Make sure it is secure

12. 12 - Exhaust Camshaft

l Check radial clearance using Plastigage (roller rocker lever removed)

l Radial play with bearing diameter 24 mm: 0.024 to 0.066 mm

l Radial play with bearing diameter 32 mm: 0.030 to 0.051 mm

l Run-out: max. 0.04 mm

13. 13 - Guide Frame

l With integrated camshaft bearings

l Clean sealing surface, reworking is not permitted.

l Remove old sealant residue.

14. 14 - Bolt

l Replace

l Tightening sequence, refer to Fig. 16

15. 15 - Camshaft Adjuster

16. 16 - Bolt

l Replace

l 20 Nm plus an additional 45° turn

17. 17 - Intake Camshaft

l Check radial clearance using Plastigage (roller rocker lever removed)

l Radial play with bearing diameter 24 mm: 0.024 to 0.066 mm

l Run-out: max. 0.04 mm

18. 18 - Chain Tensioner

l Removing and installing, refer to CAMSHAFT ADJUSTER

l Before removing, secure with locking pin T10115

19. 19 - Drive Chain

20. 20 - Bolt

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l 10 Nm

21. 21 - Bolt

l 10 Nm

22. 22 - Phase Sensor

23. 23 - Exhaust Valve

l Do not reface, only lapping is permitted

l For the correct valve dimensions, refer to Fig. 17

l Valve guides, checking, refer to VALVE GUIDES, CHECKING

24. 24 - Intake Valve

l Do not reface, only lapping is permitted

l For the correct valve dimensions, refer to Fig. 17

l Valve guides, checking, refer to VALVE GUIDES, CHECKING

25. 25 - Cap

l Replace

l Removing: When guide frame is installed: Pierce through one side of the cover with an awl and pry

it out

l Installing: Without sealant, press in 1 to 2 mm using the thrust piece 3334

Fig. 15: Cylinder Head Refacing Dimension Courtesy of AUDI OF AMERICA, LLC

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

l Minimum dimension: a = 139.20 mm

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Fig. 16: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- Replace bolts

-- Hand-tighten bolts in several stages -1 to 6- in sequence.

-- Tighten the bolts in sequence -1 to 6- to 8 Nm using a torque wrench.

-- Give 90° (1 /4 turn) additional turn in sequence -1 to 6- using rigid wrench.

NOTE:

Ensure guide frame is not tilted.

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Fig. 17: Identifying Valve Dimensions Courtesy of AUDI OF AMERICA, LLC

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

NOTE:

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

Dimension

Intake Valve

Exhaust Valve

Diameter amm33.85 ± 0.10

28.0 ± 0.1

Diameter bmm5.98 ± 0.01

5.96 ± 0.01

c

mm

104.0 ± 0.2

101.9 ± 0.2

a

Angle°

45

Component

Bolt Size

Nm

Cable Bracket

-

10

Camshaft Adjuster

1

-

20 + 45°

Camshaft Adjustment Valve 1

-

4

Camshaft Position Sensor

-

10

Camshaft Sprocket

1

-

50 + 180°

Chain Tensioner

-

10

Cylinder Head Bolt

-

40 + 180°

Exhaust Manifold Stud Bolt

-

20

Housing-10

Intake Manifold Stud Bolt

-

10

Phase Sensor

-

10

Tensioning Roller Stud Bolt

-

10

Transport Strap

-

25

Valve Housing

-

4

Toothed Belt Drive, with Divided Toothed Belt Guard

-Camshaft Sprocket

-

50 Nm + 180°

-Coolant Pump

-

15

-Crankshaft Toothed Belt Sprocket

1

-

90 + 90°

-Damper Roller for Rear Toothed Belt Guard

-

25

-Damper Roller for Sealing Flange

-

35

-Engine Mount

-

45

-Lower Toothed Belt Guard

-

8

-Rear Toothed Belt Guard

2

-

10

-Semi-Automatic Tensioning Roller, Nut

-

25

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Cylinder Head Cover Tightening Sequence

-- Install bolts -1 through 14- and tighten by hand.

Fig. 18: Identifying Cylinder Head Cover Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -1 through 14- diagonally to 10 Nm .

Cylinder Head Tightening Sequence

-- Tighten cylinder head bolts in -1 through 10- sequence as follows

-Upper Toothed Belt Guard

-

10

Toothed Belt Drive, without Divided Toothed Belt Guard

-Camshaft Sprocket

1

-

50 + 180°

-Coolant Pump

-

35

-Crankshaft Toothed Belt Sprocket

1

-

90 + 90°

-Damper Roller

-

25

-Engine Support

-

40

-Rear Toothed Belt Guard

2

-

10

-Semi-Automatic Tensioning Roller, Nut

-

25

-Upper Toothed Belt Guard

2

-

10

l

1

Replace

l

2

Insert with locking fluid

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Fig. 19: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- 1. Tighten to 40 Nm using a torque wrench.

-- 2. Tighten further 90° using a rigid wrench.

-- 3. Tighten further 90° using a rigid wrench.

Guide Frame Tightening Sequence

-- Replace bolts

-- 1. Hand-tighten bolts in several stages -1 to 6- in sequence.

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Fig. 20: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of AUDI OF AMERICA, LLC

-- 2. Tighten the bolts in sequence -1 to 6- to 8 Nm using a torque wrench.

-- 3. Give 90° (1 /4 turn) additional turn in sequence -1 to 6- using rigid wrench.

Valve Dimensions

NOTE:

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

Fig. 21: Identifying Valve Dimensions

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DIAGNOSIS AND TESTING

COMPRESSION, CHECKING

Special tools and workshop equipment required

l Compression Tester V.A.G 1763

l Spark Plug Removal Tool 3122 B

l Ignition Coil Puller T40039

l Spring Type Clip Pliers VAS 5024 A

Test Sequence

-- Remove the engine cover and air filter. Refer to Removal and Installation .

-- Remove the ignition coils with power output stage. Refer to REMOVAL AND INSTALLATION .

-- Remove spark plugs, using the 3122 B.

-- Disconnect 8-pin connector from fuel injectors. Refer to Removal and Installation

-- Check compression using the V.A.G 1763 and adapter V.A.G 1763/6.

-- Operate starter until tester shows no further pressure increase.

Compression Pressure:

Courtesy of AUDI OF AMERICA, LLC

Dimension

Intake Valve

Exhaust Valve

Diameter amm33.85 ± 0.10

28.0 ± 0.1

Diameter bmm5.98 ± 0.01

5.96 ± 0.01

c

mm

104.0 ± 0.2

101.9 ± 0.2

a

Angle°

45

NOTE:

Engine oil temperature min. 30 °C (86 °F)

Battery voltage at least 12.7 V.

NOTE:

Using tester see operating instructions.

New Bar Positive Pressure

Wear Limit Bar Positive

Pressure

Difference Between Cylinders

Bar Positive Pressure

11.0 to 14.0

7.0

Max. 3.0

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-- Install sparks plugs.

-- Install ignition coils with power output stage. Refer to REMOVAL AND INSTALLATION .

-- Read out the DTC memory of engine control module (ECM).

CAMSHAFTS, CHECKING AXIAL CLEARANCE

Special tools and workshop equipment required

l Dial Gauge Holder VW 387

l Dial Gauge 0-10 mm VAS 6079

Test Sequence

-- Perform measurement with guide frame removed.

-- Place camshaft to be checked in guide frame.

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

Fig. 22: Dial Gauge VAS 6079 Secured To Cylinder Head With Universal Dial Gauge Holder VW 387 Courtesy of AUDI OF AMERICA, LLC

-- Press camshaft against dial gauge by hand.

-- Set dial gauge to "0".

NOTE:

By separating the connections, DTCs are stored to memory. After the test, check the fault memory and erase, if necessary.

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-- Press camshaft off dial gauge and read the value:

l Axial clearance: 0.05 to 0.17 mm.

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

l Dial Gauge Holder VW 387

l Dial Gauge 0-10 mm VAS 6079

Test Sequence

-- Insert valve into guide. Valve stem end must be flush with the guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

Fig. 23: Determining Valve Rock (Wear limit) Courtesy of AUDI OF AMERICA, LLC

-- Determine tip clearance.

Wear Limit

Intake Valve Guide

Exhaust Valve Guide

0.80 mm

NOTE:

If wear limit is exceeded, measure again using new valves. If wear limit is still exceeded, replace cylinder head.

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REMOVAL AND INSTALLATION

TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD

Special tools and workshop equipment required

l Engine Support Bridge 10 - 222 A

l Shackle (1 Set=2 Pieces) 10 - 222 A /12

l Toothed Belt Tensioner T10020

l Locking Pin T10060A

Removing

-- Remove the engine cover and air filter. Refer to Removal and Installation .

-- Open cap of coolant expansion tank.

-- Remove noise insulation. Refer to Removal and Installation .

-- Remove right noise insulation fasteners -1 to 3-.

If the valve is to be replaced as part of a repair, use a new valve for the calculation.

NOTE:

Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover 25 and guard is divided in engine bracket area. Toothed belt, vehicles with divided toothed belt guard, removing and installing. Refer to TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD.

WARNING:

Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.

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Fig. 24: Identifying Fasteners Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 to 3- and the pendulum support.

Fig. 25: Identifying Pendulum Support & Bolts Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and disconnect charge air pipe with hoses.

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Fig. 26: Identifying Charge Air Pipe Bolts Courtesy of AUDI OF AMERICA, LLC

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

-- Mark the fuel line -1- and the EVAP line -2-.

Fig. 27: Fuel Line, EVAP Line And Fuel Tank

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.

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audi A3 (2006) ENGINE 2.0 Liter - General, Technical Data - Engine Code(s): BPY

Specifications and Main Features

Frequently Asked Questions

User Manual