Left Hand Shaft, Replacement

Replacement Of Complete Left-hand Balance Shaft Housing

Special tools: 5006, 5033, 5175, 5186, 5362, 5376

Turn engine until camshaft/crankshaft markings coincide:

Remove timing and balance shaft belts
See Timing/Balance Shaft Belt, Replacement. Service and Repair





Remove balance shaft pulley
Use counterhold 5362.





Remove air mass meter and inlet hose





Unbolt alternator and servo pump bracket
Undo bracket under intake manifold.

Tie bracket and assembly to wheel housing.

NOTE: Protect wheel housing from scratches.





Remove:
- bolts securing balance shaft housing to cylinder block.

Place container underneath joint (or place paper on front crossmember) to collect oil spillage from housing.





Remove balance shaft housing
Use extractor 5376.

Position tool over rear mounting point.

Separate housing from cylinder block carefully. Use tool (e.g. 5196) simultaneously to prise loose front mounting to assist in removing housing.

CAUTION: If housing is to be reused, it must be removed evenly from front and rear mountings.





Clean mounting points
Clean joint faces on cylinder block.





Place 0-rings in position
Place 0-rings in grooves around housing oilways.

Fix 0-rings in position by packing grooves with grease and lubricate housing joint faces with thin coating of grease.





Install balance shaft housing
Ensure housing is replaced evenly on front and rear mountings. Max. permissible deviation between mounting faces with reference to block is 1 mm (0.04 in).

Tighten bolts alternately in diagonal pattern. Tighten each bolt by max. 1/2 turn at a time.

Tighten bolts to 20 Nm (15 ft.lb).

Slacken and retighten to 10 Nm (7.5 ft.lb) and through a further 90°.

NOTE: Check that shaft does not seize in housing during tightening procedure.





Tighten bolted joint between housing halves
Tighten to 5 Nm (6 ft.lb).





Install drive pulley
Use counterhold 5362.

NOTE: Slot in pulley hub must be aligned with guide pin on shaft end. Shallower side of pulley must face inwards.

Tighten center bolt to 50 Nm (37 ft.lb). Use tool 5362 as counterhold.





Check axial clearance of balance shaft
Measure clearance using dial gauge mounted on magnetic stand.

Axial clearance 0.06-0.19 mm (0.0024-0.0075 in)





Install alternator and servo pump bracket
Check alternator and servo pump connections.

Reattach support under intake manifold.

NOTE: Remember to attach cable tie (clamp) to bottom bolt on support.





Install:
- air mass meter with air inlet hose and connections

NOTE: Lower engine if unit has been raised to provide access to right-hand balance shaft housing.





Install timing/balance shaft belts
See Timing/Balance Shaft Belt, Replacement. Service and Repair

NOTE: See table of tension values in specifications if replacing existing timing/balance shaft belts.