Spur gear unit, removing and installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Spur Gear Unit, Removing And Installing

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Special tools, testers and auxiliary items required

Pulling Hook T20143
Pressure piece T40051
Pressure piece T40052
Sealant

Special tools, testers and auxiliary items required

Fig 2: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

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Old oil collecting and extracting device V.A.G 1782
Hand drill with plastic brush attachment
Protective glasses
Sealant

Removing

Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
Remove engine: Vehicles with manual transmission → Engine (vehicles with manual transmission) , vehicles with automatic transmission → Engine (vehicles with automatic transmission), removing .
Disconnect engine and transmission: Vehicles with manual transmission → Engine (vehicles with manual transmission), separating , vehicles with automatic transmission → Engine and transmission (vehicles with automatic transmission), separating .
Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder: Vehicles with manual transmission → Engine (vehicles with manual transmission), securing to engine and transmission holder , vehicles with automatic transmission → Engine (vehicles with automatic transmission), securing to assembly stand .

Remove covers for timing chains → Timing chain covers (All), removing and installing .
Remove power-steering pump from cylinder block.

Fig 3: Locating Bolt On Drive Sprocket

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Loosen bolt - 1 - on drive sprocket - 2 - a few turns.
Remove chain for power take-off → Chain for power take-off, removing and installing .
Remove drive sprocket for power take-off.

Fig 4: Removing Bolts & Spur Gear Unit

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

Fig 5: Removing Compression Spring Between Spur Gear Unit And Oil Pump Input Shaft

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

Fig 6: Removing Drive Shaft For Oil Pump

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Remove drive shaft - arrow - for oil pump.

Installing

NOTE:

Replace seals and O-rings.

Fig 7: Removing A/C Compressor Drive Seal And Power Steering Pump Drive Seal Using Pulling Hook T20143/1

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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.

Fig 8: Driving In Sealing Ring For A/C Compressor Drive Using Thrust Piece T40051 & Sealing Ring For Power-Steering Pump Drive Using Thrust Piece T40052

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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.

Fig 9: Removing Drive Shaft For Oil Pump

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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 the oil pump, insert the drive shaft into the oil pump separately, do not install together with the front bearing cap.

Fig 10: Cutting Tube Nozzle At Front Marking

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

Fig 11: Applying Sealant Beads To Clean Sealing Surfaces Of Spur Gear Unit

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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.

Fig 12: Removing Compression Spring Between Spur Gear Unit And Oil Pump Input Shaft

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

Fig 13: Removing Bolts & Spur Gear Unit

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

Fig 14: Locating Bolt On Drive Sprocket

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Hand tighten power take-off drive sprocket - 2 -.
Install chain for power take-off → Chain for power take-off, removing and installing .
Tighten power take-off drive sprocket bolt - 1 -.
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 covers for timing chains Installing .
Install engine: Vehicles with manual transmission → Engine (vehicles with manual transmission), installing , vehicles with automatic transmission → Engine (vehicles with automatic transmission), installing .
Add engine oil and check oil level → Oil level, checking .

Torque specifications

Component	Nm
Spur gear unit to cylinder block	22
Drive sprocket for power take-off to shaft	62
Oil drain plug	50