Audi Workshop Service and Repair Manuals

Removing and installing spur gear drive Special tools and workshop equipment required t  Sealant → Electronic parts catalogue Removing l  Engine separated from gearbox → Chapter, engine attached to scissor-type assembly platform -VAS 6131 A- or secured to engine and gearbox support → Chapter. l  Engine oil drained → Booklet803 or → Booklet805. –  Remove clutch pressure plate → Rep. Gr.30. –  Remove dual-mass flywheel → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove oil filter housing → Chapter. –  Remove timing chain cover (bottom) → Chapter. –  Detach power steering pump from cylinder block.

–  Unscrew bolt -1- at drive chain sprocket -2- several turns. –  Remove drive 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 O-ring. –  Renew oil seals if damaged → Item and → Item. –  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.

–  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 front bearing cover).   Note

Note the use-by date of the sealant. –  Cut off tube nozzle at front marking (nozzle approx. 1 mm Ø).

–  Apply beads of sealant -arrows- onto clean sealing surfaces of spur gear drive (front) as illustrated. l  Width of sealant beads: 2.0 mm. –  Apply O-ring -1- and secure in position with a small amount of grease.   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 drive 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 cover (bottom) → Chapter. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install oil filter housing → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install timing chain covers (left and right) → Chapter. –  Install dual-mass flywheel → Chapter. –  Install clutch pressure plate → Rep. Gr.30. Tightening torques → Chapter