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How to Replace timing gears in cylinder head on Audi A4 B8 2.7 TDI quattro

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

How to Replace timing gears in cylinder head on Audi A4 B8 2.7 TDI quattro
How to Replace timing gears in cylinder head on Audi A4 B8 2.7 TDI quattro
  • 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] .

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