Spur Gear Unit: Installing

WARNING: This page is about a different car, the 2010 Audi Q7, 2009 Audi Q7, 2008 Audi Q7, and 2007 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Tightening specifications, refer to POWER TAKE-OFF OVERVIEW .

NOTE:

Replace O-ring.

-- Replace the shaft seals. Refer to item -4- POWER TAKE-OFF OVERVIEW item -12- POWER TAKE-OFF OVERVIEW , and semi-circular seal Figure in the power steering pump drive if damaged.

-- 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.

Fig 1: Drive Shaft For Oil Pump

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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:

Note the expiration date of the sealing compound.

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

Fig 2: Cut Tube Nozzle At Front Marking

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than indicated.

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

Fig 3: Applying Sealant Beads To Clean Sealing Surfaces Of Spur Gear Unit

Courtesy of AUDI OF AMERICA, LLC

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.

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

Fig 4: Identifying Compress Spring -2- For Input Shaft -3- In Spur Gear Unit -1-

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 5: Identifying Dust Cap -Arrow- On End Of Shaft For A/C Compressor Drive Spur Gear

Courtesy of AUDI OF AMERICA, LLC

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

Fig 6: Identifying Spur Gear Unit Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Install oil pump drive chain and balance shaft. Refer to POWER TAKE-OFF DRIVE CHAIN .

-- Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

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 .

-- Install the crankshaft seal on the transmission side. Refer to CRANKSHAFT SEAL, TRANSMISSION SIDE .

-- Install oil filter housing. Refer to OIL FILTER HOUSING .

-- Install intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Install left and right timing chain covers. Refer to LEFT AND RIGHT TIMING CHAIN COVERS .

-- Install drive plate. Refer to DRIVE PLATE .