Contents: Removal and installation the balance…⬇ Installing the old balance shaft…⬇ Installing a new balance shaft module ⬇ Replacing the crankshaft gear ⬇
1. The installation details of the oil pan and oil pump are shown in the accompanying illustration.
41.1 Installation details of the oil pan, oil pump and balance shaft module
1 Sealing ring, does not separate from the plug 2
2 Drain plug, must be replaced together with ring 1, 30 Nm
3 Oil pan, installed with silicone sealant D176 404A2
4, 20, 22 Bolt, 9 Nm
5 Suction tube
6, 23 Sealing ring, subject to replacement
7 Oil pump with 4.5 bar regulating valve and 10 bar safety valve
8 Oil pump drive shaft
9 Retaining ring in groove
10 Helical gear of balance shaft
11 Bolt, to be replaced, 20 Nm, then tighten to an angle of 90°
12 Thrust washer for gear 13, subject to replacement
13 Intermediate gear for balance shaft drive, subject to replacement
14 Bolt with washer, to be replaced, 90 Nm, then tighten to an angle of 90°
15 Gear hub 13, subject to replacement
16 Helical gear of crankshaft
17 Balance shaft module
18 Bolt, subject to replacement 13 Nm (M7) or 20 Nm (M8), then tighten to an angle of 90°
19 Centering bushings
21 Suction tube
24 Sensor "G266" of engine oil level and temperature
25 Self-locking bolt, subject to replacement, 9 Nm
26 Bolt, 15 Nm
2. The installation details of the oil filter housing and oil cooler are shown in the accompanying illustration.
41.2 Oil filter housing and oil cooler installation details
1 Hexagon cap 32mm, 25Nm
2-4 Sealing ring, subject to replacement
5 Filter element
6 Oil cooler
7 Bolt, 5 Nm, then 11 Nm
8 Gasket, subject to replacement
9 Bolt, to be replaced, 14 Nm, then tighten to an angle of 90°
10 Filter element and oil cooler holder
11 Gasket, subject to replacement
3. A description of the removal/installation of lubrication system parts is not provided due to the simplicity of these procedures.
Removal and installation the balance shaft module
4. Remove the crankshaft pulley.
5. Turn the crankshaft to the TDC position and lock the crankshaft gear by installing the T10050 device between the teeth on the front side (see illustration 36.13). The marks (2) on the gear wheel and on the T10050 tool (1) must be aligned when the tool pin enters the hole in the sealing flange.
6. Remove the engine oil pan.
7. Remove the bolts in the following sequence (8-1 on the accompanying illustration) and remove the balance shaft module together with the oil pump.
41.7 Sequence of tightening the balance shaft module mounting bolts (8 bolt version)
Installing the old balance shaft module
Note: If the idler gear bolt has been loosened, the crankshaft gear or the entire crankshaft has been replaced, a new idler gear must be installed and the hub must also be replaced (including bolt) and support washers. Otherwise, the backlash of the teeth will be disrupted.
8. The following procedure assumes that the crankshaft drive gear has not been replaced, the crankshaft has not been removed, and the intermediate gear has not been loosened. The crankshaft must be locked at TDC with the T10050 tool.
9. Lock the balance shaft with the T10255 tool, turning the shaft if necessary (see accompanying illustration). The pin of the T10255 device must enter the groove in the shaft.
41.9 Balance shaft lock
10. Make sure both centering bushings for the balance shaft module are in place in the cylinder block.
11. Position the locked balance shaft module on the cylinder block so that the intermediate gear meshes with the crankshaft pinion gear. The intermediate gear should also have a small amount of backlash.
12. Tighten the bolts (see illustration 41.7) fastening the balance shaft module as follows:
- bolts (1-8) - by hand;
- bolts (1-8) - with a force of 6 Nm;
- bolts (5 and 7) - with a force of 13 Nm;
- bolts (1-4, 6 and 8) - with a force of 20 Nm;
- bolts (1-8) - tighten to an angle of 90°.
13. Remove the balance shaft locking tools (T10255) and crankshaft locking tool (T10050).
14. Further installation is carried out in the reverse order of removal.
Installing a new balance shaft module
Note: The balance shaft module helical gear must be installed with the correct backlash (0.038-0.072), for which a coating is applied to the new intermediate gear. The coating wears off quickly and ensures the necessary dead play. For these reasons, a new balance shaft module should always be installed with a new intermediate gear.
15. Make sure the crankshaft is locked with the T10050 tool.
16. Before positioning the balance shaft module on the cylinder block, loosen the bolt (1 on the accompanying illustration) new intermediate gear at an angle of approximately 45°. Make sure that both centering bushings for the balance shaft module are in place and place the module on the cylinder block.
Note: Do not allow the coating on the intermediate gear to become damaged.
41.16 Intermediate gear bolt
17. Tighten the balance shaft module mounting bolts as described in paragraph 12.
18. Lock the balance shaft with the T10255 tool, turning the shaft if necessary (see illustration 41.9). The pin of the T10255 device must enter the groove in the shaft.
19. Carefully place the balance shaft gear onto the balance shaft, while slightly pushing the intermediate gear to the side. Make sure that the threaded holes in the balance shaft are aligned with the oblong holes in the gear. If the oblong holes in the gear cannot be aligned with the threaded holes in the shaft, the balance shaft gear should be installed turned a certain number of teeth further. Tighten the gear fasteners securely (see accompanying illustration) and remove the T10255 device.
41.19 Balance shaft gear bolts
20. Get an assistant and do the above steps simultaneously. Rest against the intermediate gear (3 on the accompanying illustration) wooden block and press it firmly in the direction of the arrow into the teeth of the drive gear (2) and the gear (1) of the balance shaft. At the same time, slightly turn the gear (1) counterclockwise.
41.20 Installing the intermediate gear
Tighten the idler gear bolt securely.
21. Remove the crankshaft locking device (T10050). After this, the dead play should not be felt when lightly pressing with your hand.
22. Further installation is carried out in the reverse order of removal.
Replacing the crankshaft gear
23. Remove the front sealing flange (see Section 37).
24. Remove the balance shaft module (see the relevant subsection above).
25. Insert support T10392/1 into the end of the crankshaft (see accompanying illustration).
41.25 Support T10392/1
26. Install the T10392 puller into the gear holes (see accompanying illustration) and turn it clockwise, then screw in the centering pins (A).
41.26 Puller T10392
27. Holding the crankshaft with a wrench (And on the accompanying illustration), pull the gear off the crankshaft by screwing in the spindle with the key (B).
41.27 Removing the crankshaft gear
28. Make sure the end of the crankshaft is clean.
29. Place the new gear on the hotplate with the marking facing up, heat the gear to a temperature of 200-240°C, grab it with Swedish pliers or tongs and quickly install it on the crankshaft without tilting until it stops using tool No.10-203 (see accompanying illustration).
41.29 Installing the crankshaft gear
Note: When holding the gear, be careful not to damage the gear teeth. If the gear is heated to 200°C, you only have 4 seconds to install it; at higher temperatures, there is more time: for example, at 220°C, the gear can be installed within 6 seconds. To monitor the gear temperature, use a suitable thermometer or multimeter in combination with a temperature sensor. Wear heat-protective gloves.
30. Allow the gear to cool for a few minutes and install the balance shaft module.