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 A/C compressor drive dust cap - arrow -.






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

- Remove the bolt - arrow - and remove the power steering pump or the power steering pump (V119) from the 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 5 - in a diagonal sequence.






- First loosen the spur gear unit from the bonding and then remove it.

- Remove the oil pump input shaft - arrow -.






Installing

• Tightening specifications, refer to => [ Spur Gear Unit, Tightening Specifications and Sequence ] Power Take-Off Overview.

• Replace O-ring.

- Replace the shaft seals, item - 3 - => [ (Item 3) Shaft Seal ] Power Take-Off Overview, item - 6 - => [ (Item 6) Shaft Seal ] Power Take-Off Overviewand the semi-round ring. Refer to => [ Semi-Circular Seal Installation Location ] Power Take-Off Overview in the power steering pump drive, if damaged.

- Remove any sealant still on the spur gear unit and cylinder block.

- Clean the 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.

- 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.

• Use a hose clamp appropriate for the model, refer to the electronic parts catalog ETKA.

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






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

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

- Install the power steering pump or the power steering pump.

- 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.