Spur Gear Unit

Spur Gear Unit

Special tools, testers and auxiliary items required

• Old Oil Collecting and Extracting Device (V.A.G 1782)

• Sealant

Removing

- Remove rear noise insulation by loosening fasteners - 1 and 2 -.





• Ignore items - 3 and 4 -.

- Place Old Oil Collecting and Extracting Device (V.A.G 1782) under engine and drain engine oil.

- Remove automatic transmission.

- Remove drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Remove intake manifold.

- Remove oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Remove lower timing chain cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

- Remove power-steering pump from cylinder block.

- Remove hose clamp at A/C compressor dust cap - arrow -.





- Remove power take-off drive chain. Refer to => [ Power Take-Off Drive Chain ] Power Take-Off Drive Chain.

- 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 driveshaft - arrow - for oil pump.





Installing

• Tightening specifications. Refer to => [ Power Take-Off Assembly Overview ] Power Take-Off Assembly Overview.

• Replace O-ring.

- Replace shaft seals => [ (Item 12) Power steering pump driveshaft seal ] Power Take-Off Assembly Overview, => [ (Item 4) A/C compressor driveshaft seal ] Power Take-Off Assembly Overview and semi-circular seal => [ Semi-circular seal installation location ] Power Take-Off Assembly Overview in the power steering pump drive if damaged.

- Remove sealant residue on spur gear unit and cylinder block.

- Clean sealing surfaces so they are completely free of any oil or grease.

- Insert driveshaft - arrow - for oil pump into guide on oil pump.





• To guarantee that the driveshaft engages correctly in the oil pump, insert the driveshaft into the oil pump separately, do not install together with the front bearing cap.

- Cut tube nozzle at front marking (nozzle dia. approximately 1.5 mm).





CAUTION!
The lubrication system could be plugged with excess sealant.

• Do not apply sealant beads thicker than indicated.

- 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.

• 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 -.





- Slide the dust cap - arrow - onto the end of the shaft for the A/C compressor drive spur gear with the hose clamp already installed and secure it.





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





- Install power take-off drive chain. Refer to => [ Power Take-Off Drive Chain ] Power Take-Off Drive Chain.

- 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 lower timing chain cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

- Install crankshaft seal, transmission side. Refer to => [ Transmission-Side Crankshaft Sealing Ring, Replacing ] Service and Repair.

- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Install intake manifold.

- Install left and right timing chain covers => [ ] Left and Right Timing Chain Covers.

- Install drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Install automatic transmission.

- Add engine oil and check oil level. Refer to => [ Oil Level, Checking ] Component Tests and General Diagnostics.