How to Replace timing gears on Audi A8 (D3) 3.0 TDI Quattro 2003-2010

Special tools

• Camshaft alignment tool – No.T40094.
• Camshaft holding tool – No.T40095.
• Crankshaft locking pin – No.3242.
• High-pressure fuel pump belt camshaft sprocket holding tool – No.3036.
• High-pressure fuel pump belt camshaft sprocket puller – No.T10320.
• Two-piece gear alignment tool – No.T40096.

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 gears.
• Do NOT turn crankshaft or camshaft with timing gear(s) removed.

Valve timing procedures

• Removal/installation of timing gears requires:
  • Timing chain removal.
  • Removal of high-pressure fuel pump belt.
  • Removal of high-pressure fuel pump belt camshaft sprocket.
  • Removal of camshafts.
  • Camshaft sprocket removal.
• Engine at TDC on No.1 cylinder.
• Remove blanking plug from sump [1] .
• Install crankshaft locking pin [2] .
• LH bank:
  • Fit exhaust camshaft on camshaft alignment tool [3] .
  • Ensure camshaft alignment tool engages in end of camshaft [4] .
  • Align gear teeth of two-piece exhaust camshaft gear with camshaft gear alignment tool [5] .
  • Fit inlet camshaft on camshaft alignment tool [6] .
  • Ensure camshaft alignment tool engages in end of camshaft [7] .
  • Move exhaust camshaft in direction of arrow to engage teeth of camshaft gears [8] .
  • Fit camshaft housing on camshafts [9] .
  • Retain camshafts in position with camshaft holding tool [10] .
  • Disengage camshaft alignment tool from end of camshaft [4] .
  • Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
  • Place camshaft housing with camshafts and special tools on cylinder head [9] .
  • Ensure crankshaft locking pin located correctly [1] .
  • Refit camshaft housing [9] .
  • Install LH timing chain.
  • Remove special tools [5] & [10] .
• RH bank:
  • Fit exhaust camshaft on camshaft alignment tool [11] .
  • Ensure camshaft alignment tool engages in end of camshaft [12] .
  • Fit inlet camshaft on camshaft alignment tool [13] .
  • Ensure camshaft alignment tool engages in end of camshaft [14] .
  • Align gear teeth of two-piece inlet camshaft gear with camshaft gear alignment tool [15] .
  • Move exhaust camshaft in direction of arrow to engage teeth of camshaft gears [16] .
  • Fit camshaft housing on camshafts [9] .
  • Retain camshafts in position with camshaft holding tool [10] .
  • Disengage camshaft alignment tool from end of camshaft [12] .
  • Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
  • Place camshaft housing with camshafts and special tools on cylinder head [9] .
  • Ensure crankshaft locking pin located correctly [1] .
  • Refit camshaft housing [9] .
  • Install RH timing chain.
  • Remove special tools [15] & [10] .