Spur gear unit, removing and installing

WARNING: This page is about a different car, the 2010 Audi A8, 2009 Audi A8, 2008 Audi A8, and 2007 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

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Special tools, testers and auxiliary items required

Extractor hook T20143
Pressure piece T40051
Pressure piece T40052

Special tools, testers and auxiliary items required

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Old oil collecting and extracting device V.A.G 1782
Sealant

Removing

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Remove rear sound insulation by loosening fasteners - 1 and 2 -.

NOTE:

Ignore items - 3 and 4 -.

Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
Remove automatic transmission → 37 - CONTROLS, HOUSING .
Remove drive plate → Drive plate, removing and installing .
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .

Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove oil filter housing → Oil filter housing, removing and installing .
Remove lower timing chain cover → Timing chain lower cover, removing and installing .
Remove power-steering pump from cylinder block.

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Remove hose clamp at A/C compressor dust cap - arrow -.
Remove power take-off drive chain → Power take-off drive chain, removing and installing .

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Remove bolts - 1 to 6 -.
Remove spur gear unit.

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

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Remove drive shaft - arrow - for oil pump.

Installing

Tightening torque → Power take-off, assembly overview .

NOTE:

Replace sealing rings and O-rings.

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Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using pulling hook T20143/1.
Remove O-ring - 1 -.
Remove sealant residue on spur gear unit and cylinder block.
Clean sealing surfaces so they are completely free of any oil or grease.

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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.

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Insert drive shaft - arrow - for oil pump into guide on oil pump.

NOTE:

To guarantee that the drive shaft engages correctly in oil pump, insert drive shaft only into oil pump, do not install together with front bearing cap.

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Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1.5 mm).

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

Thickness of sealant beads: 2.0 mm.

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

NOTE:

The spur gear unit must be installed within 5 minutes after application of sealant.

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

NOTE:

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

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

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Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.
Install power take-off drive chain → Power take-off drive chain, removing and installing .
Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

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

Install lower timing chain cover → Timing chain lower cover, removing and installing .
Install crankshaft seal, transmission side → Transmission-side crankshaft sealing ring, replacing .
Install oil filter housing → Oil filter housing, removing and installing .
Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .

Install left and right timing chain covers Installing .
Install drive plate → Drive plate, removing and installing .
Install automatic transmission → 37 - CONTROLS, HOUSING .
Add engine oil and check oil level → Oil level, checking .