11 27 030 Removing and refitting/replacing balancer shafts (B48AO0)

Special tools required:

00 2 300
2 288 054
2 361 286
64 1 020

Necessary preliminary work:

NOTE: To facilitate disassembly and installation, rotate engine with special tool 00 2 300 to a more convenient working position .
In the following operations, the engine is rotated for 180 degrees. Bottom points upwards.

Removal:

Release all bolts (arrows).

Guide out and remove the oil deflector (1).

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Lever out both sealing caps (1) with screwdriver (2).

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Twist crankshaft to top dead center first cylinder .

Mount special tool 2 288 054 and abut screws (1).

Observe installation note in next operation!

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NOTE: Make sure special tool 2 288 054 is properly seated in the guides (1) of the counterbalance shaft (2).
Slightly twist crankshaft if necessary.
Tighten special tool 2 288 054 to 20 N.m .

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Release screws (1).

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Release screws (1).

Guide the special tool 2 288 054 out and remove.

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NOTE: The gear is pressed onto the counterbalance shaft with a taper and can only be released with special tool 2 361 286.

Screw in special tool 2 361 286 into the gear of the counterbalance shaft and secure by means of open-end spanner (1).

Release counterbalance shaft with screw (2) from gear.

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Attention!

Risk of damage on crankcase!

Do not under any circumstances drop counterbalance shafts (1) into the bearing positions!

Carefully remove counterbalance shafts (1) from crankcase towards front.

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Check all needle bearings of the counterbalance shafts.

If necessary, pull off and replace all needle bearing of the counterbalance shafts.

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Remove gear (1).

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Remove gear (1).

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Slacken nut (1).

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Remove gear (1).

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Installation:

NOTE: All marks on the gears (1 and 2) and on the intermediate gearwheel (3) must point vertically towards the oil sump sealing surface (upwards).

Mark on gear (1) on intake side: Triangle
Mark on gear (2) on exhaust side: Two rectangles
Mark on the intermediate gear (3) on the exhaust side: One square

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Parts: Replace gear (1).

Install gear (1).

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Move gear (1) in direction of arrow on the gear (2).

Tighten nut (3).

Tightening torque 11 27 2AZ .

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Attention!

Risk of mixing up (similar parts) gears!

Gear (1) is marked with an (A) and has to be installed on the exhaust side!

Parts: Replace gear (1).

Mount gear (1).

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Attention!

Risk of mixing up (similar parts) gears!

Gear (1) is marked with an (E) and has to be installed on the intake side!

Parts: Replace gear (1).

Mount gear (1).

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Attention!

Risk of damage on crankcase!

Do not under any circumstances drop counterbalance shafts (1) into the bearing positions!

Carefully install counterbalance shafts (1) in crankcase.

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Slide special tool 64 1 020 or any other suitable tool through the gear into the counterbalance shaft.

Carefully insert counterbalance shaft (1) into the gear on the intake side.

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Slide special tool 64 1 020 or any other suitable tool through the gear into the counterbalance shaft.

Carefully insert counterbalance shaft (1) into the gear on the exhaust side.

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Screw both bolts (1) into the counterbalance shafts on the left and right.

NOTE: Do not tighten screws (1) because otherwise the counterbalance shafts cannot be positioned in the next operation.

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Twist crankshaft to top dead center first cylinder.

Mount special tool 2 288 054 and abut screws (1).

Observe installation note in next operation!

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NOTE: Make sure special tool 2 288 054 is properly seated in the guides (1) of the counterbalance shaft (2).
Slightly twist crankshaft and/or counterbalance shafts if necessary.
Tighten special tool 2 288 054 to 20 N.m.

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Tighten down screws (1).

Tightening torque 11 27 1AZ .

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Release screws (1) and remove special tool 2 288 054.

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Parts: Replace sealing cap (1).

Ensure proper fit of O-ring.

Install both sealing caps (1).

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Parts: Replace screws.

Feed in and install oil deflector (1).

Tighten all bolts (arrows).

Tightening torque: 11 41 3AZ / 11 41 4AZ .

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Required follow-up work:

Install OIL PUMP WITH VACUUM PUMP .
Install the REAR TIMING CASE COVER .
Remove ENGINE FROM ASSEMBLY STAND .
Install ENGINE WITH TRANSMISSION .