Spur Gear Unit

Spur Gear Unit

Special tools, testers and auxiliary items required

• Old oil collecting and extracting device (VAG 1782)

Removing

- Remove engine. Refer to => [ Engine, Removing ] Engine, Removing.

- Separate engine and transmission. Refer to=> [ Separating transmission from engine ] Engine, Removing.

- Secure engine on the engine and transmission holder (VAS 6095). Refer to => [ Engine, Securing on Engine and Transmission Holder ] Engine, Securing on Engine and Transmission Holder.

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

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

- Remove intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

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

- 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.

- Remove dust cap - arrow - together with Air Conditioning (A/C) compressor input shaft from shaft end of A/C compressor drive spur gear.





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

- Remove bolts - 1 through 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

- Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using extractor hook (T20143/1).

- Remove O-ring - 1 -.





• Replace seals and O-rings.

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

- Remove sealant residue on front bearing cap and on cylinder block.

- Clean the sealing surfaces, they must be free of oil and 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 driveshaft - arrow - for oil pump into guide on oil pump.





• To guarantee that the driveshaft engages correctly in oil pump, insert driveshaft only into oil pump, do not install together with spur gear unit.

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





- Apply sealant beads - arrows - on clean sealing surfaces of front bearing cap as shown in illustration.





• Thickness of sealant beads: 2.0 mm.

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

• The bearing cap must be installed within 5 minutes after application of sealant.

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





- Slide dust seal cap - arrow - with hose clamp already installed onto shaft end of A/C compressor drive spur gear.





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





- Install oil pump drive chain and balance shaft. 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 the installation is performed in reverse order of removal, noting the following:

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

- Install crankshaft seal, timing chain side. Refer to => [ Crankshaft Seal, Timing Chain Side ] Service and Repair.

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

- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

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

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

- Install engine. Refer to => [ Engine, Installing ] Engine, Installing.

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

Tightening Specifications