Installing Balance Shaft On Intake Side

> 138755 - REPLACING BALANCE SHAFT SEALING RING (R4) 

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Balance shafts

1. 2.1  Oil the mount for the new balance shaft on the intake side with engine oil.
2. 2.2  Insert balance shaft on intake side -1-  into cylinder block.
3. 2.3  Replace screw for balance shaft on intake side -4-  .
4. 2.4  Fit and tighten screw for balance shaft on intake side -4-  .

   > Initial - tightening torque 4 Nm (3 ftlb.) 

   > Final tightening torque + 45° 

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Bearing pin for intermediate shaft gearwheel

1. 3.1  Pull bearing pin for intermediate shaft gearwheel -2-  from cylinder block.
2. 3.2  Replace O-ring -1-  .
3. 3.3  Insert bearing pin for intermediate shaft gearwheel -2-  into cylinder block. Make sure that dowel pin -3-  of the bearing pin for intermediate shaft gearwheel -2-  engages in the bore on the cylinder block.

Information 

The intermediate shaft gearwheel must be replaced.

The new intermediate shaft gearwheel has an anti-friction coating that wears off after a short time, thereby setting the correct tooth backlash automatically.

If the intermediate shaft gearwheel is not replaced, there is a danger of engine damage due to incorrect tooth backlash.

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Intermediate shaft gearwheel

1. 4.1  Align balance shaft -3-  so that the markings on balance shaft -Arrow A-  and intermediate shaft gearwheel -Arrows B-  are aligned.
2. 4.2  Copy marking -Arrows B-  on intermediate shaft gearwheel -1-  onto the teeth using a coloured marker to make it easier to fit intermediate shaft gearwheel -1-  .
3. 4.3  Fit new intermediate shaft gearwheel -1-  .
4. 4.4  Check that markings -Arrows-  are aligned correctly.
5. 4.5  Replace screw on intermediate shaft gear wheel -2-  .
6. 4.6  Fit and tighten screw on intermediate shaft gearwheel -2-  .

   > Initial - tightening 10 Nm (7.5 ftlb.) 

   Check intermediate gear for play by turning. If there is play on the intermediate gear: Loosen and tighten again.

   > Final - tightening 25 Nm (19 ftlb.) 

   > Torque angle + 90° 

Information 

The screw of the coolant pump drive belt pulley has a left-hand thread.

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Coolant pump drive gear

1. 5.1  Fit coolant pump drive wheel -1-  on the balance shaft -3-  .
2. 5.2  Replace screw -2-  .
3. 5.3  Screw in new screw -2-  as far as it will go by hand and then loosen by about three turns.

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TDC marking

1. 6.1  Check that markings -Arrows-  for TDC position of the crankshaft are aligned.
2. 6.2  Apply marking on cylinder block -1-  using a permanent marker.

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Marking on sprocket

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Balance shaft timing chain

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Sprocket (three-stage)

1. 9.1  Insert sprocket -1-  into balance shaft timing chain -2-  so that markings -A and B-  are aligned.
2. 9.2  Fit sprocket -1-  on crankshaft -Arrow-  .

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Thrust piece on sprocket

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Balance shaft timing chain

1. 11.1  Install guide rail -1-  .
   1. 11.1.1  Position guide rail -1-  .
   2. 11.1.2  Fit and tighten guide pins -5-  .

      > Tightening - torque 20 Nm (15 ftlb.) 

2. 11.2  Install tension rail -2-  .
   1. 11.2.1  Position tension rail -2-  .
   2. 11.2.2  Fit and tighten guide pins -4-  .

      > Tightening - torque 20 Nm (15 ftlb.) 

3. 11.3  Fit and tighten chain tensioner -3-  using screw-locking agent.

   > Tightening - torque 85 Nm (63 ftlb.)