Spur Gear Unit
Spur Gear Unit
Special tools, testers and auxiliary items required
• Sealant, refer to the Electronic Parts Catalog (ETKA)
Removing
• The transmission is removed.
- Remove the left exhaust manifold. Refer to => [ Left Exhaust Manifold ] Left Exhaust Manifold.
- Remove the bolts - arrows - and the heat shield - 1 -.
- Remove the hose clamp on the Air Conditioning (A/C) compressor drive dust cap - arrow -.
- Remove timing chain lower cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.
- Disconnect the power steering pump from the guide frame.
- Remove the power take-off drive chain. Refer to => [ Power Take-Off Drive Chain ] Power Take-Off Drive Chain.
- Loosen and remove the bolts - 1 through 6 - in a diagonal sequence.
- First loosen the spur gear unit from the bonding and then remove it.
Through VIN CAU 003 685:
- Remove the compression spring - 2 - between the spur gear unit - 1 - and oil pump input shaft - 3 -.
Continued for All Engines:
- Remove the oil pump input shaft - arrow -.
Installing
• Tightening specification, refer to => [ Spur Gear Unit, Tightening Specifications and Sequence ] Power Take-Off Overview.
• Replace the O-ring.
- Replace the shaft seals => [ (Item 12) Shaft Seal for the Power Steering Pump Drive ] Power Take-Off Overview => [ (Item 4) Air Conditioning (A/C) Compressor Driveshaft Seal ] Power Take-Off Overview and the semi-round ring in the power steering pump drive, if damaged. Refer to => [ Semi-Circular Seal Installation Location ] Power Take-Off Overview.
- Remove the sealant residue on the spur gear unit and on the cylinder block.
- Clean the running and sealing surfaces; they must be free of oil and grease.
- 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.
• Note the expiration date of the sealing compound.
- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).
The lubrication system could be plugged with excess sealant.
• Do not apply sealant beads thicker than indicated.
- 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.
Through VIN CAU 003 685:
- Insert the compression spring - 2 - for the input shaft - 3 - in the spur gear unit - 1 -.
Continued for All Engines:
- Position the spur gear unit and tighten the bolts. Refer to => [ Spur Gear Unit, Tightening Specifications and Sequence ] Power Take-Off Overview.
- Install the power take-off drive chain. Refer to => [ Power Take-Off Drive Chain ] Power Take-Off Drive Chain.
- Install the power steering pump with the new O-ring on the power steering pump drive spur gear.
- 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 in reverse order of removal paying attention to the following:
- Install timing chain lower cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.
- Install the left exhaust manifold. Refer to => [ Left Exhaust Manifold ] Left Exhaust Manifold.