Contents: Balance shaft drive chain ⬇ Balance shaft on the intake side ⬇ Balance shaft on the exhaust side ⬇
Balance shaft drive chain
1. The details of the installation of the balance shafts and their chains are shown in the accompanying illustration.
29.1 Details of installation of balance shafts and their chains
1, 10 Bolt, 9 Nm
2 Balance shaft on the exhaust side, lubricate the bearing with engine oil
3 Balance shaft tube
4 Chain tensioner, 65 Nm
5 Cylinder block
6 Balance shaft on the intake side, lubricate the bearing with engine oil
7 Sealing ring
8 Bearing support, lubricate with engine oil
9 Intermediate shaft with gear and sprocket, after loosening bolt 12, must be replaced
11 Washer
12 Bolt, subject to replacement, after loosening replace shaft 9
13, 19 Chain guide bar 17
14, 16, 20 Guide pins, 20 Nm
15 Chain tension bar 17
17 Balance shaft drive chain
18 Crankshaft sprocket
2. Remove the timing chain and its tensioner (see Section 28).
3. Remove the tensioner (1 on the accompanying illustration) balance shaft chains, its tension (2) and guide (3 and 4) bars, and then the chain itself.
29.3 Removing the balance shaft chain
4. Turn the intermediate shaft sprocket and balance shaft so that the mark on the balance shaft is between the marks on the intermediate shaft gear (arrow on the accompanying illustration).
29.4 Installation position of the intermediate shaft
Note: It may be necessary to complete up to 7 shaft revolutions.
5. Place the balance shaft drive chain on the sprockets so that its colored links are opposite the marks on the balance shaft sprockets and on the crankshaft sprocket (see accompanying illustration).
29.5 Marks on the balance shaft chain and on the sprockets
6. Install the guide strips (4 and 3 in Illustration 29.3) and the tension bar (2) of the balance shaft drive chain, and then tighten the tensioner (1).
7. Again, make sure that the mark on the balance shaft is between the marks on the intermediate shaft gear (see illustration 29.4), and also that the colored links of the chain are opposite the marks on the sprockets (see illustration 29.5).
8. Install the timing chain tensioner and the timing chain itself (see Section 28).
Balance shaft on the intake side
9. Remove the water pump drive toothed belt (see Chapter 3).
10. Remove the balance shaft chain (see subsection above).
11. Unscrew the bolt (1 in illustration 29.4) and remove the intermediate shaft with the gear.
12. Unscrew the bolt (2 on the accompanying illustration) and pull out the balance shaft on the intake side.
29.12 Balance shaft mounting bolts
Note: If the shaft cannot be removed by hand, use a puller (grips and a sliding hammer).
13. Lubricate the balance shaft bearing with engine oil and install the shaft into the cylinder block. The shaft should be installed by hand; otherwise it should be cooled first (keep in the freezer for about 30 minutes, or use a special cooling spray).
14. Install a new sealing ring (1 on the accompanying illustration), lubricate the bearing support with engine oil and install it so that the centering pin (arrow) fits into the hole in the cylinder block.
29.14 Installing the bearing support
15. Prepare a new intermediate shaft (9 in illustration 29.1). If you use the old shaft, there will be no play between the gear teeth, which will damage the engine. The gear of the new intermediate shaft has a special coating that wears off soon after starting work and provides the necessary play.
16. Mark with paint the edges of the intermediate gear teeth, marked with dots on the end face (see accompanying illustration), and then slide the idler gear onto the bearing support so that the marked teeth are on either side of the tooth marked on the balance shaft gear.
29.16 Installing the intermediate shaft
17. Make sure that the marks on the intermediate and balance shaft gears match (see illustration 29.4), and tighten the new bolt (1) to 10 Nm. Turn the sprocket (there should be no play, otherwise loosen and tighten the bolt again), tighten the bolt to a force of 30 Nm and finally tighten the bolt to an angle of 90°. Again, make sure that the marks on the gears are correctly aligned.
18. Install the balance shaft drive chain (see subsection above).
19. Replace the water pump drive oil seal and install the water pump drive toothed belt (see Chapter 3).
Balance shaft on the exhaust side
20. Remove the balance shaft chain (see subsection above).
21. Unscrew the bolt (1 in illustration 29.12) and pull out the balance shaft on the exhaust side.
Note: If the shaft cannot be removed by hand, use a puller (grips and a sliding hammer).
22. Make sure that the protrusion of the balance shaft tube enters the hole in the cylinder block (see accompanying illustration).
29.22 Installation position of the camshaft tube
Note: To install the tube, squeeze it.
23. Lubricate the balance shaft bearing with engine oil and install it into the cylinder block. The shaft should be installed by hand; otherwise it should be cooled first (keep in the freezer for about 30 minutes, or use a special cooling spray).
24. Make sure the balance shaft is flush with the cylinder block and tighten the bolt (1 in illustration 29.12) shaft fastenings.
25. Install the balance shaft drive chain (see the relevant subsection above).