Balance Shaft Installation

Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft-to-balance shaft timing must be established. Refer to  BALANCE SHAFT TIMING  . 

1. With balance shafts installed in carrier position carrier on crankcase and install four attaching bolts and tighten to 54 N.m (40 ft. lbs.). See Figure.
2. Turn balance shafts until both shaft key ways are up, 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 with gear timing marks meshed as shown in Fig 1.
   Fig 1: Gear Timing

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - KEY WAYS UP

   2 - GEAR ALIGNMENT DOTS

3. Install gear cover and tighten double ended stud/washer fastener to 12 N.m (105 in. lbs.).
4. Align flat on balance shaft drive sprocket to the flat on crankshaft. See Fig 2.
5. Install balance shaft drive sprocket on crankshaft using Special Tool 6052. See Fig 3.
   Fig 2: Balance Shaft Sprocket Alignment to Crankshaft

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - ALIGN FLATS

   Fig 3: Balance Shaft Drive

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - SPROCKET

   2 - SPECIAL TOOL 6052

6. Turn crankshaft until number 1 cylinder is at top dead center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. See Fig 4.
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 4.
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 4.
   NOTE: The lower plated link is 8 links from the upper link.
9. With balance shaft keyways pointing up (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.
   Fig 4: 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 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.
11. CHAIN TENSIONING: 
    • Install chain tensioner loosely assembled.
    • 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 mm (0.039 in.) thick x 70 mm (2.75 in.) long or 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 in Fig 5.
    • With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 N.m (105 in. lbs.). Remove shim.
    • Install carrier covers and tighten screws to 12 N.m (105 in. lbs.).
12. Install pick-up tube and oil pan.
13. Fill engine crankcase with proper oil to correct level.

Fig 5: Chain Tension Adjustment

Courtesy of DAIMLERCHRYSLER CORP.