Spur Gear Unit

Spur Gear Unit

Special tools, testers and auxiliary items required

• Sealant

Removing

• Engine and transmission separated, refer to => [ Engine and Transmission, Separating ] Engine and Transmission, Separating, engine on the scissor lift platform (VAS 6131 A) or secured by the engine/transmission holder, refer to => [ Engine, Securing to Engine and Transmission Holder ] Engine, Securing to Engine and Transmission Holder.

• Engine oil drained.

- Remove the 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 the intake manifold.

- Remove the 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 the power steering pump from the cylinder block.

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





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

- Remove the bolts - 1 to 6 -.





- Remove the spur gear from the bond.

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





- Remove driveshaft - arrow - for oil pump.





Installing

• Replace O-ring.

- Replace the shaft seals - 4 - => [ A/C Compressor Driveshaft Seal ] Power Take-Off Assembly Overview, - 12 - => [ Power Steering Pump 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 O-ring - 1 -.





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

- Clean the sealing surfaces, they must be free of oil and 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.

• Note the expiration date of the sealing compound.

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





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





• Sealant bead thickness: 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 -.





• Use a hose clamp appropriate for the model.

- 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.





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





- 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.





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

- Slide the power steering pump onto the power steering pump drive spur gear.

The rest of the 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 the transmission-side crankshaft shaft seal. Refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.

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

- Install the intake manifold.

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

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

- After installing the engine, fill with oil and then check the level.

Tightening Specifications