Table of contents: Removal ↓ Installation ↓
Removal
Remove the poly V-belt. Remove the toothed belt: toothed belt drive with hydraulically damped tension roller, toothed belt drive with friction-damped tension roller. Remove the oil pan. Remove the sealing flange from the belt pulley side. Unscrew the bolts "arrows". Unlock the 5 fastening brackets and remove the oil separator.
Press in the chain tensioner and secure it with the "T10060 A" lock "arrow". Unscrew the intermediate sprocket "1" from the crankshaft frame. Unscrew the bolt "2" and remove the chain tensioner. Remove the chain from the sprockets and place it on a clean mat.
Lock the balance shaft with a spanner SW 24/27 "pos. 1" as shown in the figure. The spanner must be aligned with the center of the balance shaft counterweight and is perpendicular to the balance shaft. Loosen the bolt "2" of the counterweight using the spanner "T10061". Only loosen the bolts, do not unscrew them.
Unscrew the crankshaft frame "3" from the cylinder block and remove it together with the balance shaft. Place the crankshaft frame on a clean mat. Unscrew the counterweight bolt and remove the counterweight and sprocket. Turn the balance shaft so that it can be removed from the support.
Installation
Installation is in the reverse order, in this case it is necessary to replace the O-ring. Replace the bolts, which are additionally tightened to the appropriate angle. Lubricate the working surfaces of the support with oil and insert the balance shaft. Install the sprocket and counterweight on the balance shaft. The sprocket and counterweight can only be installed in one position. Tighten the counterweight and sprocket bolt by hand. Before installing the crankshaft frame, check the installation of the centering bushings in the cylinder block and the installation of the O-ring in the crankshaft frame. Screw the crankshaft frame "3" to the cylinder block by hand and align it. The crankshaft frame must be flush with the outer edge of the cylinder block on the belt pulley side. Screw the crankshaft frame crosswise in several stages. Lock the balance shaft with a SW 24/27 spanner "pos. 1", as shown in the figure. The spanner must be aligned with the center of the balance shaft counterweight and is perpendicular to the balance shaft. Tighten the counterweight with a new bolt "2". Install the chain tensioner. Clean the chain with a rag. Check that the "arrow" mark is located on top of the crankshaft sprocket.
Install the chain on the crankshaft, oil pump and balance shaft sprockets. The markings on the crankshaft and balance shaft sprockets must match the chain links marked with a colored marker "arrows".
Instructions: The chain links marked with a colored marker should be additionally marked with a zigzag.
Insert the intermediate sprocket into the chain and screw it to the crankshaft frame. Remove the lock from the chain tensioner.
Check that the markings on the crankshaft and balance shaft sprockets match the chain links marked with a colored felt-tip pen "arrows". Install the sealing flange on the belt pulley side. Install the oil separator with a new sealing ring, to do this: lubricate the sealing ring with oil, lubricate the inner rod of the oil separator with oil, check the correct installation of the sealing tape, make sure that the oil separator snaps into the crankshaft frame. Install the oil pan. Install the toothed belt (adjust valve timing): toothed belt drive with hydraulically damped tension roller, toothed belt drive with friction-damped tension roller. Install the poly V-belt.
Tightening torques:
- Crankshaft frame with balance shaft to cylinder block: 14 Nm + 180° 1)
- Counterweight with sprocket to crankshaft frame: 100 Nm + 90° 1)
- Chain tensioner to crankshaft frame: 8 Nm + 90° 1)
- Intermediate sprocket to crankshaft frame: 20 Nm
- Oil separator to crankshaft frame: 5 Nm
1) Replace the bolts.