Spur Gear Unit, Removing and Installing

Spur gear unit, removing and installing
Items required
^ Sealant; Refer to Parts Supplier

Removing
- Drain off engine oil.
- Remove engine.
- Separate engine/transmission assembly.
- Place engine on workbench or a firm surface and secure in position with wooden blocks.

WARNING:
^ Engine must be secure to avoid risk of accident
^ Do not set down engine on oil pan.

- Remove drive plate.
- Remove covers for timing chains.
- Detach power steering pump from cylinder block.





- Loosen bolt -1- at drive sprocket -2- a few turns.
- Remove PTO chain.
- Unscrew drive sprocket for PTO chain.





- Screw out bolts -1- to -8,
- Detach rear bearing cap for spur gear unit.





- Detach spur gears in sequence -1- to -3-.





- Take spring -1- out of shaft for drive spur gear.
- Detach O-rings -2,
- Screw out bolt (arrow).
- Detach front bearing cap from cylinder block.





- Pull out drive shaft (arrow) for oil pump.

Installing

Note: Replace sealing rings and O-rings.





- Use mandrel to drive out sealing rings -2- (for AC compressor drive) and -3- (for power steering pump drive) from front.
- Detach O-ring -1 -.
- Remove remnants of sealant at front bearing cap and cylinder block.
- Clean sealing surfaces; they must be free from oil and grease.
- Drive in sealing ring for power steering pump drive/AC compressor drive.





- Insert drive shaft (arrow) for oil pump in guide at oil pump.

Note: To ensure proper engagement of drive shaft in oil pump, insert shaft separately in oil pump (not together with front bearing cap).





- Cut off nozzle of tube at front mark (diameter of nozzle approximately 1 mm).

Note: Covers for timing chains must be installed within 5 minutes after applying silicone sealant





- Apply silicone sealant beads (arrows) as shown to clean sealing surfaces of front bearing cap.
^ Thickness of sealant bead: 1.5 to 2.0 mm
- Install O-ring -1- and fix in position with a small quantity of grease.





- Install front bearing cap and hand-tighten bolt (arrow).
- Insert spring -1 -.
- Install O-rings -2- and fix in position with a small quantity of grease.





- Insert spur gears -1- to -3-.





- Attach dust cap (arrow) to end of shaft of spur gear for AC compressor drive.
- Check whether the 2 dowel sleeves have been installed in the rear bearing cap and insert if necessary.





- Install rear bearing cap and tighten bolts as follows.
1. Bolts 1, 3, 7
^ To 10 Nm
2. Bolts 2, 4, 5, 6, 8, 9
^ Diagonally and in stages
- Hand-tighten drive sprocket for PTO chain.
- Install PTO chain.





- Tighten drive sprocket for PTO chain to 62 Nm.
- Slide power steering pump with new O-ring onto spur gear for power steering pump drive.

Perform further installation in reverse order, note the following:
- Install covers for timing chains.
- Install drive plate.
- Bolt transmission to engine and install engine/transmission assembly
- Pour in engine oil and check oil level.





Tightening torques