How to Replace timing chain on Audi A4 B8 3.0 TDI quattro

Special tools

• Camshaft holding/alignment tool – No.T40061.
• Camshaft locking pin x 2 – No.T40060.
• Camshaft sprocket holding tool – No.T40062.
• Crankshaft turning tool 1 – No.T40058.
• Crankshaft turning tool 2 – No.T40049.
• Crankshaft locking pin – No.3242.
• Injection pump/balancer shaft locking pin – No.3359.
• Primary timing chain tensioner locking tool – No.40071.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Timing chains located at rear of engine.
• Removal/installation of timing chain requires:
  • Gearbox/drive plate removal.

NOTE: All bolts with an angular torque setting MUST be replaced.

• Turn crankshaft until just before TDC on No.1 cylinder.
• Remove blanking plug from sump [1] .
• Install crankshaft locking pin [2] .
• Slowly turn crankshaft pulley clockwise until locking pin can be inserted in crankshaft [1] . Tighten to 20 Nm.
• Ensure hole in RH camshaft sprocket at 7 o’clock position [3] .
• Ensure hole in LH camshaft sprocket at 5 o’clock position [4] .
• If not, remove crankshaft locking pin and turn crankshaft 1 turn.
• Install camshaft locking pin as shown [5] .
• Rotate camshaft locking pins to alignment position [6] .

NOTE: The side pin of each camshaft locking pin must be in line with centre of camshaft sprocket.

• Ensure balancer shaft can be locked in position [7] .
• Lock timing chain tensioners in retracted position before carrying out engine repairs:
  • Push plunger into tensioner housing [8] .
  • Insert 3,3 mm pin to lock tensioner plunger [9] .
  • Fit primary timing chain tensioner locking tool [10] .

NOTE: If camshaft locking pins cannot be fitted valve timing is incorrect.

• If necessary, slacken bolts of each camshaft sprocket 1 turn [11] .
• Rotate LH camshaft until camshaft locking pin can be fitted [5] .
• Rotate camshaft locking pin to alignment position [6] .
• Repeat procedure for RH camshaft alignment.
• Hold LH camshaft with holding/alignment tool.
• Tighten LH camshaft sprocket bolts [11] . Tightening torque: 5 Nm.
• Remove LH camshaft locking pin [5] .
• Remove camshaft holding/alignment tool.
• Tighten LH camshaft sprocket bolts [11] . Tightening torque: 23 Nm.
• Repeat procedure for RH camshaft alignment.
• Remove crankshaft locking pin [2] .
• Release timing chain tensioner after repairs [9] & [10] .
• Turn crankshaft two turns clockwise until just before TDC on No.1 cylinder.
• Install crankshaft locking pin [2] .
• Slowly turn crankshaft pulley clockwise until locking pin can be inserted in crankshaft [2] .
• Ensure camshaft locking pin can be inserted [5] .
• Rotate camshaft locking pins to alignment position [6] .

NOTE: The side pin of each camshaft locking pin must be in line with centre of camshaft sprocket.