Balance Shaft Installation/Timing

Fig 1: Balance Shafts and Carrier Assembly

Courtesy of DAIMLERCHRYSLER CORP.

Balance shaft (6) and carrier (4) assembly installation is the reverse of the removal procedure. During installation crankshaft-to-balance shaft timing must be established. Refer to  TIMING BELT  . 

1. With balance shafts (6) installed in carrier (4) position carrier on crankcase and install four attaching bolts and tighten to 54 N.m (40 ft. lbs.). See Fig 1.
   Fig 2: Gear Timing

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - KEY WAYS UP

   2 - GEAR ALIGNMENT DOTS

2. Turn balance shafts until both shaft key ways are up (1), parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up (1) with gear timing marks meshed (2) as shown. See Fig 2.
3. Install gear cover and tighten double ended stud/washer fastener to 12 N.m (105 in. lbs.).
   Fig 3: Balance Shaft Sprocket Alignment to Crankshaft

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - ALIGN FLATS

4. Align flat on balance shaft drive sprocket to the flat on crankshaft (1). See Fig 3.
   Fig 4: Balance Shaft Drive

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - SPROCKET

   2 - SPECIAL TOOL 6052

5. Install balance shaft drive sprocket on crankshaft using Balance Shaft Sprocket Installer 6052 (2). See Fig 4.
   Fig 5: Balance Shaft Timing

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - MARK ON SPROCKET

   2 - KEYWAYS UP

   3 - ALIGN MARKS

   4 - PLATED LINK

   5 - PARTING LINE (BEDPLATE TO BLOCK)

   6 - PLATED LINK

6. Turn crankshaft until number 1 cylinder is at top dead center (TDC). The timing marks on the chain sprocket (1) should line up with the parting line (5) on the left side of number one main bearing cap. See Fig 5.
7. Place chain over crankshaft sprocket so that the plated link of the chain is over the number 1 cylinder timing mark on the balance shaft crankshaft sprocket. See Fig 5.
8. Place balance shaft sprocket into the timing chain and align the timing mark on the sprocket (dot) with the (lower) plated link on the chain. See Fig 5.
   Fig 6: Balance Shaft Timing

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - MARK ON SPROCKET

   2 - KEYWAYS UP

   3 - ALIGN MARKS

   4 - PLATED LINK

   5 - PARTING LINE (BEDPLATE TO BLOCK)

   6 - PLATED LINK

   NOTE: The lower plated link(4) is 8 links from the upper link (6).
9. With balance shaft keyways pointing up (2) (12 o'clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance.
   NOTE: The timing mark on the sprocket, the (lower) nickel plated link, and the arrow on the side of the gear cover should line up when the balance shafts are timed correctly.
10. If the sprockets are timed correctly, install the balance shaft bolts and tighten to 28 N.m (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation.
    Fig 7: Chain Tension Adjustment

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - 1MM (0.039 IN.) SHIM

    2 - TENSIONER (ADJUSTER) BOLT

    3 - SHOULDERED PIVOT BOLT

11. CHAIN TENSIONING: 
    • Install chain tensioner (2) loosely assembled with new  adjuster screw and shouldered pivot screw.
    • Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 N.m (105 in. lbs.).
    • Place a shim (1) 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long between tensioner and chain. Push tensioner and shim up against the chain. Apply firm pressure 2.5-3 Kg (5.5-6.6 lbs.) directly behind the adjustment slot to take up all slack.  Chain must have shoe radius contact as shown. See Fig 7.
    • With the load applied, tighten top tensioner adjuster bolt (2) first, then bottom shouldered pivot bolt (3). Tighten bolts to 12 N.m (105 in. lbs.). Remove shim (1).
    • Install carrier covers and tighten screws to 12 N.m (105 in. lbs.).
12. If removed, install oil pump (Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)  .
13. Install pick-up tube and oil pan (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)  .
14. Fill engine crankcase with proper oil to correct level.