Spur Gear Unit

Spur Gear Unit

Special tools, testers and auxiliary items required

• Sealant

Removing

• The transmission is removed.

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

- Remove the hose clamp on the A/C compressor drive dust cap - arrow -.





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

- Remove bolts - 1 to 6 -.





- Remove the spur gear unit.

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





- Remove the oil pump input shaft - arrow -.





Installing

• Replace O-ring.

- Replace the shaft seal => [ (Item 3) Power steering pump driveshaft seal ] Power Take-Off Assembly Overview, and semi-circular seal => [ (Item 13) Drive spur gear for power take-off with semi-circular seal ] Power Take-Off Assembly Overview in the power steering pump drive if damaged.

- Remove O-ring - 1 -.





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

- Insert the oil pump input shaft - arrow - in the guide on the 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.

• Use a hose clamp appropriate for the model.





- Because of limited space, the new hose clamp - 1 - must slide through the hole in the guide frame, over the dust cap - 3 - and onto the A/C compressor input shaft - 2 - while the spur gear unit is still removed.

• Note the expiration date of the sealing compound.

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





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

• Do not apply sealant bead thicker than specified.

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





• Thickness of sealant beads: 2.0 mm.

- Install a new O-ring - 1 - and secure it with some grease.

• Install the spur gear unit within five minutes of applying the sealant.

- Insert the compression spring - 2 - for the input shaft - 3 - in the spur gear unit - 1 -.





- Position the spur gear unit and tighten the bolts. Refer to => [ Spur Gear Unit, Tightening Specifications and
Sequence ] Power Take-Off Assembly Overview.





• Secure the dust cap with a hose clamp appropriate to model.

- Slide the dust cap - arrow - with pre-installed hose clamp on the end of the spur gear shaft for the A/C compressor drive.





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

The rest of the installation is in reverse order of removal, note the following:

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

- Fill the engine oil.

- Fill with coolant => [ Filling ] Procedures.