Balance Shaft Gear: Service and Repair

Balance Shaft Spur Gear

Special tools, testers and auxiliary items required

• Oil Seal Driver (10-203)

• Commercially Available Hot Plate

• Puller (T10392) with

• Pressure Piece (T10392/1)

• Digital Thermometer (VAS 6519)

• Protective Gloves

Removing

- Remove the belt pulley side sealing flange. Refer to => [ Sealing Flange, Belt Pulley Side ] Service and Repair.

- Remove the balance shaft module. Refer to => [ Balance Shaft Module ] Balance Shaft Module.

- Insert the thrust piece (T10392/1) in the crankshaft pins.






- Insert the puller (T10392) in the spur gear holes and rotate it clockwise - arrow -. Install the locking pin - A -.






- Counter-hold the crankshaft with an open end wrench - A -. Remove the spur gear by installing the spindle with the open end wrench - B - or ratchet.






Installing

• Check the temperature with the digital thermometer (VAS 6519) when heating the new spur gear.

• When the temperature reaches 200 °C (392 °F), there are about four seconds to position the spur gear on the crankshaft.

• A higher temperature increases the amount of time available for positioning (220 °C (392 °F) = approximately six seconds).

• Make sure the crankshaft pins are clean.


Do not exceed the maximum temperature of 240 °C (464 °F). Otherwise the spur gear will discolor and possibly become distorted.

- Lay the entire surface of the new spur gear on a commercially available hot plate and heat it to at least 200 °C (392 °F) (maximum 240 °C (464 °F)). The coating faces upward.







There is a risk of burns. Wear suitable protective gloves during the rest of the procedure.

- After the temperature is reached, remove the spur gear from the plate with pliers as illustrated.






• Make sure the splines on the spur gear are not damaged.

- Quickly slide the spur gear by onto the crankshaft pins as far as the stop. Use the oil seal driver (10-203) for assistance and do not tilt the gear.






- Let the spur gear cool a few minutes.

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

- Install the balance shaft module. Refer to => [ Balance Shaft Module ] Balance Shaft Module.

- Install the belt pulley side sealing flange. Refer to => [ Sealing Flange, Belt Pulley Side ] Service and Repair.