New Balance Shaft Assembly, Installing

New Balance Shaft Assembly, Installing

Special tools, testers and auxiliary items required

• Locking Tool (T10255)

Procedure

• Tightening specifications, refer to => [ Oil Pump, Oil Pan and Balance Shaft Module Assembly Overview ] Oil Pump, Oil Pan and Balance Shaft Module Assembly Overview.

• Secure the crankshaft with the crankshaft stop (T10050).

• The spur gear drive for the balance shaft assembly must be installed with a backlash of 0.038 to 0.072 mm.

• The new intermediate sprocket has a coating in the correct thickness to make sure the backlash is correct. The coating is on parts of the circumference of the teeth.

• The coating wears off in a short time and the backlash is correct.

• A new balance shaft assembly must always be installed with a new intermediate sprocket having the coating.

• To make sure the installed position is correct, there is a white dot on the intermediate sprocket.

• Intermediate sprockets not having a white dot have coating all the way around. The installed position is the same.

• Replace bolts which have been tightened to an additional torque.


Danger of the axial bearing disc slipping behind the intermediate gear.

• Do not loosen the bolt for the intermediate shaft sprocket more than specified when mounting the balance shaft assembly. Axial bearing disc installation position => [ Axial Bearing Disc Installed
Position ] Oil Pump, Oil Pan and Balance Shaft Module Assembly Overview.

- Loosen the bolt - 1 - for the intermediate sprocket approximately 45°.





- Install the alignment bushings for centering the balance shaft assembly on the cylinder block if they are missing.

- Position the balance shaft module on the cylinder block. Make sure the partially coated intermediate sprocket is positioned correctly:

• The white dot - arrow - on the intermediate sprocket must be centered with the crankshaft.





• Intermediate sprocket without the white dot can be installed in any position.

• Do not damage the coating on the intermediate sprocket.

• Due to the gear ratio, the white dot - arrow - will not be in the original location after rotating the crankshaft.

- Tighten the bolts for the balance shaft assembly => [ Balance Shaft Assembly - Tightening
Specification and Sequence ] Oil Pump, Oil Pan and Balance Shaft Module Assembly Overview.





- Lock the balance shaft in place with the (T10255). Turn the balance shaft if necessary.





• The locking tool pins must engage in the groove on the balance shaft.

- Carefully mount the balance shaft chain sprocket on the balance shaft. Push the intermediate sprocket slightly to the side when doing this.

• Do not damage the coating on the intermediate sprocket.

• The threaded holes in the balance shaft should be, if possible, in the center of the oblong holes in toothed gear.

• If the slots on the balance shaft chain sprocket cannot be aligned with the threaded holes in the cover, rotate the sprocket the corresponding number of teeth and position it again.

- Tighten the bolts - arrows - for the balance shaft chain sprocket.





- Remove the (T10255).

• The following 3 steps must be performed at the same time. A second technician will be needed.

- Press the intermediate gear - 3 - forcefully in direction of - arrow - into the spur gear splines - 2 - and the balance shaft chain sprocket - 1 - using a wooden block if necessary.





- Turn the balance shaft chain sprocket counter-clockwise slightly while doing this.

- Tighten the bolt for the intermediate gear.

- Remove the (T10050).

• The intermediate sprocket must not have any angular clearance after installation. This can be checked by pressing slightly with the hand.

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

- Install oil pan. Refer to => [ Oil Pan ] Service and Repair.

- Fill the engine oil and check the level.

- Install vibration damper. Refer to => [ Vibration Damper ] Service and Repair.