diff --git a/tools/update_zuul_project_configs.py b/tools/update_zuul_project_configs.py
index 4fe5374b..ff3e0727 100644
--- a/tools/update_zuul_project_configs.py
+++ b/tools/update_zuul_project_configs.py
@@ -130,6 +130,7 @@ def process_repositories(args, service):
         zuul_templates = None
         zuul_jobs = dict()
         zuul_new_jobs = list()
+        zuul_vars = dict()
         zuul_config_updated = False
         for item in zuul_config:
             if "project" in item.keys():
@@ -137,10 +138,11 @@ def process_repositories(args, service):
                 zuul_templates = project.setdefault("templates", [])
                 if not zuul_templates:
                     zuul_templates = []
+                zuul_vars = project.setdefault("vars", {})
             elif "job" in item.keys():
                 job = item["job"]
                 zuul_jobs[job["name"]] = job
-        print(f"Existing jobs {zuul_jobs}")
+        logging.debug(f"Existing jobs {zuul_jobs}")
         if "helpcenter-base-jobs" not in zuul_templates:
             zuul_templates.append("helpcenter-base-jobs")
             zuul_config_updated = True
@@ -148,6 +150,7 @@ def process_repositories(args, service):
         job_suffix = (
             "-hc-int-jobs" if args.environment == "internal" else "-hc-jobs"
         )
+        sphinx_pdf_files = zuul_vars.setdefault('sphinx_pdf_files', [])
         for doc in data.docs_by_service_type(service["service_type"]):
             logging.debug(f"Analyzing document {doc}")
             if not doc.get("type"):
@@ -156,6 +159,12 @@ def process_repositories(args, service):
                 doc_type = "dev-guide"
             else:
                 doc_type = doc["type"]
+            # Collect all PDF files into sphinx_pdf_files var
+            pdf_name = doc.get('pdf_name')
+            if pdf_name and f"{pdf_name}.pdf" not in sphinx_pdf_files:
+                sphinx_pdf_files.append(f"{pdf_name}.pdf")
+                zuul_config_updated = True
+
             template_name = f"{doc_type}{job_suffix}"
             if doc_type in ["api-ref", "umn", "dev-guide"]:
                 if template_name not in zuul_templates:
@@ -190,6 +199,7 @@ def process_repositories(args, service):
                 if "project" in item.keys():
                     project = item["project"]
                     project["templates"] = zuul_templates
+                    project["vars"] = zuul_vars
                     # Ensure new jobs are in check
                     if len(zuul_new_jobs) > 0:
                         project.setdefault(