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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

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