Spur Gear Unit, Removing and Installing

Spur gear unit, removing and installing





Special tools, testers and auxiliary items required
^ Pulling Hook T20143
^ Pressure piece T40051
^ Pressure piece T40052
^ Sealant

Special tools, testers and auxiliary items required





^ Old oil collecting and extracting device VAG 1782
^ Hand drill with plastic brush attachment
^ Protective glasses
^ Sealant

Removing
- Place old oil collecting and extracting device VAG 1782 under engine and drain engine oil.
- Remove engine.
- Disconnect engine and transmission.
- Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder:
- Vehicles with manual transmission.
- Remove covers for timing chains.
- Remove power-steering pump from cylinder block.





- Loosen bolt - 1 - on drive sprocket - 2 - a few turns.
- Remove chain for power take-off.
- Remove drive sprocket for power take-off.





- Remove bolts - 1 to 6 -.
- Remove spur gear unit.





- Remove compression spring - 2 - between spur gear unit - 1 - and oil pump input shaft - 3 -.





- Remove drive shaft - arrow - for oil pump.

Installing

Note:
^ Replace seals and O-rings.





- Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using pulling hook T20143/1.
- Remove O-ring - 1 -.
- Remove sealant residue on spur gear unit and cylinder block.
- Clean sealing surfaces so they are completely free of any oil or grease.





- Drive in sealing ring for A/C compressor drive using thrust piece T40051.
- Drive in sealing ring for power-steering pump drive using thrust piece T40052.





- Insert drive shaft - arrow - for oil pump into guide on oil pump.

Note:
^ To guarantee that the drive shaft engages correctly in the oil pump, insert the drive shaft into the oil pump separately, do not install together with the front bearing cap.





- Cut off nozzle on tube of sealant at front mark (dia. of nozzle approximately 1.5 mm).





- Apply sealant beads - arrows - to clean sealing surfaces of spur gear unit as shown in illustration.

^ Thickness of sealant beads: 2.0 mm.

- Position O-ring - 1 - and secure it with some grease.

Note:
^ The spur gear unit must be installed within 5 minutes after application of sealant.





- Position compress spring - 2 - for input shaft - 3 - in spur gear unit - 1 -.





- Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.





- Hand tighten power take-off drive sprocket - 2 -.
- Install chain for power take-off.
- Tighten power take-off drive sprocket bolt - 1 -.
- Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

The rest of installation is in reverse order of removal, note the following:
- Install covers for timing chains.
- Install engine.
- Add engine oil and check oil level.

Torque specifications