Balance Shaft Module

Balance Shaft Module

=> [ New Balance Shaft, Installing ]

=> [ Used Balance Shaft Module, Installing ]

Special tools, testers and auxiliary items required

• Crankshaft Stop (T10050) for engines with a round crankshaft toothed belt gear

• Locking Tool (T10255)

Removing

- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Remove the vibration damper.

- Remove the lower toothed belt guard.

- Remove the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Rotate the engine to Top Dead Center (TDC) and secure the crankshaft toothed belt gear using he crankshaft stop (T10050). Push the crankshaft stop from the front side of the toothed belt gear into the teeth. The camshaft toothed gear must be in the 12 o'clock position.






• The marks on the crankshaft toothed belt gear - 2 - and the crankshaft stop (T10050) - 1 - must align. The pin on the crankshaft stop (T10050) must engage in the hole on the sealing flange.

- Remove the bolts in sequence - 8 through 1 - and remove the balance shaft module with the oil pump.






New Balance Shaft, Installing

Conditions






• Secure the crankshaft with the crankshaft stop (T10100).

• The balance shaft module spur gear must be installed with the correct backlash.

• A coating is applied to the new intermediate sprocket to achieve the correct backlash.

• If the intermediate sprocket has a white dot, the coating covers only parts of the circumference. If there is no white dot, the entire circumference of the intermediate sprocket is coated.

• The coating wears off in a short period of time and ensure the correct backlash.

• For this reason, a new balance shaft module must always be installed in conjunction with a new intermediate sprocket with coating.

• Only intermediate sprockets with a partial coating have a white dot to indicate the correct installed position.

• There is no installed position to follow for intermediate sprockets with coating on the entire circumference.

• Replace bolts which have been tightened to a torque angle.


• The intermediate shaft threaded connection must be loosened to position the balance shaft module. When doing so, make sure the bolt is not loosened too much. Otherwise the bearing disc could slip behind the intermediate sprocket.

• Axial bearing disc installed position, refer to => [ Axial Bearing Disc Installed Position ] Oil Pump, Pan and Balance Shaft Module Overview.

- Before positioning the balance shaft module on the cylinder block, loosen the intermediate sprocket bolt - 1 - approximately 45° (1/8 turn).






- Make sure both alignment sleeves for centering the balance shaft module on the cylinder block are present.

- 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.

• Make sure the coating on the intermediate sprocket is not damaged.

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

- Install the new bolts in the sequence - 1 to 8 - and tighten them by hand.






- Tighten the balance shaft module bolts as follows:

- Tighten the nuts in sequence - 1 through 8 - to 6 Nm.

- Tight the bolts - 5 and 7 - to 13 Nm.

- Tighten the bolts - 5 and 7 - an additional 90° (1/4) turn using a ratchet.

- Tighten the bolts - 1 through 4, 6 and 8 - to 20 Nm.

- Tighten the bolts - 1 through 4, 6 and 8 - an additional 90° (1/4)) turn using a rachet.

- Secure the balance shaft using locking tool (T10255). Rotate the balance shaft if necessary.






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

- Carefully position the balance shaft spur gear on the balance shaft while pressing the intermediate sprocket to the side slightly.






• Make sure the threaded holes on the balance shaft align and are centered as much as possible in the slots on the balance shaft spur gear.

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

- Tighten the balance shaft spur gear - arrows -.

- Remove the locking tool (T10255).

The follow three steps must be performed at the same time (a second technician is required):






- Using a wooden block to assist if necessary, press the intermediate shaft - 3 - forcefully in the - direction of the arrow - into the splines on the crankshaft spur gear - 2 - and balance shaft spur gear - 1 -.

- Rotate the balance shaft spur gear counterclockwise slightly when doing so.

- Tighten the new bolt for the intermediate sprocket:

• Tightening specification, see - item 12 - in => [ Oil Pump, Pan and Balance Shaft Module Overview ] Oil Pump, Pan and Balance Shaft Module Overview.

- Remove the crankshaft stop (T10100).

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

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

- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Install the lower toothed belt guard:

• Tightening specification, see - item 27 - in => [ Toothed Belt Overview ] Toothed Belt Overview.

- Install the vibration damper.

• Tightening specification, see - item 28 - in => [ Toothed Belt Overview ] Toothed Belt Overview.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

Used Balance Shaft Module, Installing

Conditions






• Secure the crankshaft with the crankshaft stop (T10100).


• A new intermediate sprocket with coating must be installed and the hub including the bolt and axial bearing discs must be replaced if the intermediate shaft bolt was loosened, the crankshaft spur gear was replaced or the crankshaft was removed. Otherwise the backlash will be incorrect.

• Installation procedure, refer to => [ New Balance Shaft, Installing ].

• Proceed as follows if the used balance shaft module will be installed again and if the crankshaft spur gear was replaced or the crankshaft was removed. Do not loosen the intermediate sprocket under any circumstances.

• Replace bolts which have been tightened to a torque angle.

- Secure the balance shaft with the locking tool (T10255). Rotate the balance shaft if necessary.






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

- Make sure both alignment sleeves for centering the balance shaft module on the cylinder block are present.

- Position the balance shaft module on the cylinder block.

• The intermediate shaft must engage in the spur gear on the crankshaft when the balance shaft is secured in place.

• The intermediate sprocket must have slight angular clearance.

- Install the new bolts in sequence - 1 through 8 - and tighten them by hand.






- Tighten the balance shaft module bolts as follows:

- Tighten the nuts in sequence - 1 through 8 - to 6 Nm.

- Tight the bolts - 5 and 7 - to 13 Nm.

- Tighten the bolts - 5 and 7 - an additional 90° (1/4) turn using a ratchet.

- Tighten the bolts - 1 through 4, 6 and 8 - to 20 Nm.

- Tighten the bolts - 1 through 4, 6 and 8 - an additional 90° (1/4)) using a ratchet.

- Remove the crankshaft stop (T10100).

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

- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Install the lower toothed belt guard:

• Tightening specification, see - item 27 - in => [ Toothed Belt Overview ] Toothed Belt Overview.

- Install the vibration damper.

• Tightening specification, see - item 28 - in => [ Toothed Belt Overview ] Toothed Belt Overview.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.