Removing and installing spur gear drive: VW Touareg I 4.2 (BAR, CGNA, CKDA)

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Renewed: oil seals

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• Replace oil seals and O-rings.Secure dust cap with the correct type of hose clip (same as original equipment) ETKA (Electronic Parts Catalogue).
• Clean sealing surfaces; they must be free of oil and grease.
• To ensure correct engaging of drive shaft in oil pump, insert drive shaft separately into oil pump (NOT together with spur gear gearbox).
• Cut off tube nozzle at forward marking (∅ of nozzle approx. 1.5 mm).
• The bearing cover must be installed within 5 minutes after applying sealant.

🔧 Engine codes this applies to

📋 Procedure

1. Remove engine .
2. Separate engine and gearbox .
3. Secure engine to engine and gearbox supportVAS 6095.
4. Remove drive plate .
5. Remove left and right timing chain covers .

6. Remove intake manifold .
7. Remove oil filter housing .
8. Remove lower timing chain cover .
9. Pull power steering pump off cylinder block.
10. Remove hose clip.
11. Pull dust cap (arrow), together with air conditioner compressor drive shaft, off stub shaft of spur gear for air conditioner compressor drive.
12. Remove drive chain for auxiliary drives .
13. Unscrew bolts (1 … 6).
14. Remove spur gear gearbox.
15. Remove spring (2) between spur gear gearbox (1) and oil pump drive shaft (3).
16. Remove drive shaft (arrow) for oil pump.
17. Pull out oil seals for air conditioner compressor drive (2) and for power steering pump drive (3) using extractor tool T20143/1.
18. Remove O-ring (1). [Note: Replace oil seals and O-rings.Secure dust cap with the correct type of hose clip (same as original equipment) Electronic Parts Catalogue.]
19. Remove sealant residue from front bearing cover and cylinder block.
20. Clean sealing surfaces; they must be free of oil and grease.
21. Drive in new oil seal for air conditioner compressor drive using thrust piece T40051.
22. Drive in new oil seal for power steering pump drive using thrust piece T40052.
23. Insert drive shaft (arrow) for oil pump into guide sleeve at oil pump. [Note: To ensure correct engaging of drive shaft in oil pump, insert drive shaft separately into oil pump (NOT together with spur gear gearbox).]
24. Cut off tube nozzle at forward marking (∅ of nozzle approx. 1.5 mm).
25. Apply beads of sealant (arrows) onto clean sealing surfaces of front bearing cover as illustrated.
26. Install O-ring (1) and secure in position with a small amount of grease. [Note: The bearing cover must be installed within 5 minutes after applying sealant.]
27. Install spring (2) in spur gear gearbox (1) for drive shaft (3).
28. Slide dust cap (arrow), along with installed hose clip, onto stub shaft of spur gear for air conditioner compressor drive.
29. Fit spur gear gearbox and tighten bolts (1 … 6) in stages and in diagonal sequence.
30. Install drive chain for auxiliary drives, oil pump and balancer shaft .
31. Slide power steering pump with new O-ring onto power steering pump drive spur gear.
32. Install lower timing chain cover .
33. Install crankshaft oil seal on timing chain side .
34. Install oil filter housing .
35. Install intake manifold .
36. Install left and right timing chain covers .
37. Install drive plate .
38. Install engine .
39. Fill with engine oil and check oil level .

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