Right Hand Shaft, Replacement

Replacement Of Complete Right-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 drive pulley
Use counterhold 5362.





Remove:
- balance shaft belt tensioner
- bolt between rear section of transmission mounting plate and balance shaft housing





Remove air mass meter and air inlet hose





Remove:
- air preheating hose from bottom heat shield under exhaust manifold
- nuts securing right-hand engine mounting to member





Lift engine using right-hand lifting lug
Use lifting yoke 5006, two support bars 5003, and lifting hooks 5115 and 5186.

NOTE: Check clearance between master cylinder and intake manifold.





Remove engine mounting
Remove complete mounting (including insulating pad and lower mounting plate) from block.





Remove:
- bolts attaching 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 aligned 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 (3.5 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 engine mounting
Install mounting complete with insulating pad and lower mounting plate.





Lower engine into position on front crossmember
Use studs on member to guide lower engine mounting plate into position.

Remove lifting attachments.





Install air mass meter with air inlet hose and connections





Retighten:
- engine mounting
- air preheating hose





Install:
- bolt in rear section of transmission mounting plate
- belt tensioner, tightening bolt so that pulley is movable when belt is placed in position
- 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.