Audi Workshop Service and Repair Manuals

Removing and installing spur gear drive

Special tools and workshop equipment required

t	Extractor tool -T20143-

t	Thrust piece -T40051-

t	Thrust piece -T40052-

t	Sealant → Parts catalogue

t  Used oil collection and extraction unit -V.A.G 1782- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue Removing –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Remove engine: Vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Separate engine and gearbox: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Leave engine on scissor-type assembly platform -VAS 6131 A- or secure it to engine and gearbox support: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Remove timing chain covers → Chapter. –  Detach power steering pump from cylinder block.

–  Unscrew bolt -1- at drive chain sprocket -2- several turns. –  Remove chain for auxiliary drives → Chapter. –  Unbolt drive chain sprocket for auxiliary drives.

–  Remove bolts -1 ... 6-. –  Remove spur gear drive.

–  Remove spring -2- between spur gear drive -1- and drive shaft -3- for oil pump.

–  Remove drive shaft -arrow- for oil pump.

Installing   Note Renew seals and O-rings. –  Pull out oil seals -2- (for AC compressor drive) and -3- (for power steering pump drive) using extractor tool -T20143/1-. –  Remove O-ring -1-. –  Remove sealant residue from spur gear drive and cylinder block. –  Clean sealing surfaces; they must be free of oil and grease.

–  Drive in the oil seal for AC compressor drive using thrust piece -T40051-. –  Drive in the oil seal for power steering pump drive using thrust piece -T40052-.

–  Insert drive shaft -arrow- for oil pump into guide sleeve at oil pump.   Note To ensure that drive shaft engages correctly in oil pump, insert drive shaft separately into oil pump (NOT together with spur gear drive).

–  Cut off tube nozzle at front marking (nozzle approx. 1.5 mm Ø).

–  Apply the beads of sealant -arrows- onto the clean sealing surfaces of the spur gear drive as illustrated. l  Width of sealant beads: 2.0 mm. –  Apply a small amount of grease to O-ring -1- and fit in position.   Note The spur gear drive must be installed within 5 minutes after applying the sealant.

–  Insert spring -2- for drive shaft -3- in spur gear drive -1-.

–  Fit spur gear drive and tighten bolts -1 ... 6- in diagonal sequence and in stages.

–  Fit drive chain sprocket -2- for auxiliary drives and tighten bolt hand-tight. –  Install chain for auxiliary drives → Chapter. –  Tighten bolt -1- on drive chain sprocket for auxiliary drives to final torque. –  Press power steering pump with new O-ring onto spur gear for power steering pump drive. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers → Anchor. –  Install engine: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Fill up with engine oil and check oil level → Chapter. Tightening torques

Component	Nm
Spur gear drive to cylinder block	22
Drive chain sprocket for auxiliary drives to shaft	62
Oil drain plug	50