How to Replace timing chain on Audi A4 B8 2.7 TDI quattro

Audi 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

How to Replace timing chain on Audi A4 B8 2.7 TDI quattro
  • 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.

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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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