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

Special tools

  • Camshaft locking pin x 2 – No.T40060.
  • Crankshaft alignment tool – No.T40049.
  • Crankshaft locking pin – No.3242.
  • Crankshaft pulley alignment tool – No.T40058
  • Injection pump/balancer shaft locking pin – No.3359.

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(s) requires:
      • Sump removal.
      • Gearbox/drive plate removal.
  • Turn crankshaft until just before TDC on No.1 cylinder. Tool No.T40049.
  • Remove blanking plug from sump [1] .
  • Slowly turn crankshaft pulley clockwise until locking pin can be inserted in crankshaft [2] . Tool No.3242.
  • Remove timing chain LH & RH upper covers [3] & [4] .
  • Remove the camshaft sprocket bolt positioned at 5 o’clock on RH camshaft sprocket [5] .
  • Remove the camshaft sprocket bolt positioned at 7 o’clock on LH camshaft sprocket [6] .
  • Ensure balancer shaft can be locked in position [7] . Tool No.3359.
  • Ensure both camshafts can be locked in position [8] . Tool No.T40060.

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

  • Lock timing chain tensioners in retracted position before carrying out engine repairs:
      • Push plunger into tensioner housing [9] .
      • Insert 3,3 mm pin to lock tensioner plunger [10] .

NOTE: Upper chain tensioner bolts MUST only be used once.

  • If necessary, slacken bolts of each camshaft sprocket 1 turn [11] .
  • Rotate camshaft until camshaft locking pin can be fitted [8] . Tool No.T40060.
  • Rotate camshaft locking pin to alignment position [12] . Tool No.T40060.

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

  • Ensure threaded holes positioned centrally in slots of camshaft sprocket and balancer shaft sprocket [13] & [14] .

NOTE: Camshaft sprocket bolts MUST only be used once.

  • Tighten camshaft sprocket bolts to 5 Nm [11] .
  • Remove camshaft locking pins [8] & [12] . Tool No.T40060.
  • Tighten camshaft sprocket bolts to 23 Nm [11] .
  • Remove crankshaft locking pin [2] . Tool No.3242.
  • Release timing chain tensioner after repairs [10] .
  • Install blanking plug [1] .

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