Table of contents: Removal ↓ Installation ↓
Removal
Remove the poly V-belt. Remove the toothed belt. Remove the oil pan. Remove the front sealing flange.
Unscrew the "arrow" bolts. Unlock the 5 fasteners and remove the oil separator.
Press the chain tensioner and secure it with the locking pin "T10060 A" or "T10060" "arrow". Unscrew the freewheel sprocket "1" from the crankshaft frame. Unscrew the bolts "2" of the chain tensioner and remove the tensioner. Remove the chain from the sprockets and place it on a clean surface.
Fix the balance shaft with a 24/27 spanner, pos. "1", as shown in the figure. The spanner should be aligned coaxially with the counterweight, setting it at a right angle to the balance shaft. Loosen bolt "2" on the counterweight using the "T10061" attachment.
Instructions: Do not unscrew the bolt, just loosen it.
Unscrew the crankshaft frame "3" from the cylinder block and remove it together with the counterweight. Place the frame on a clean surface. Unscrew the bolt on the counterweight and remove the counterweight and sprocket. Turn the balance shaft so that it can be removed from the supports.
Installation
Installation is in the reverse order, while observing the following: Replace the sealing ring. Replace the bolts tightened to a certain angle. Lubricate the working surfaces of the supports and install the balance shaft. Install the sprocket and counterweight on the balance shaft. The sprocket and counterweight are installed in one position only. Screw in the counterweight/sprocket bolt all the way. Before installing the crankshaft frame, make sure that the cylinder block centering sleeve and the sealing ring are present in the crankshaft frame. Screw the crankshaft frame to the cylinder block by hand and align it. The crankshaft frame on the belt pulley side must be flush with the outer edge of the cylinder block. Fully tighten the crankshaft frame bolts crosswise in several steps. Secure the balance shaft with a 24/2 7 mm wrench "pos. 2" as shown in the figure. The wrench should be aligned coaxially with the counterweight, installed at a right angle to the balance shaft. Screw the counterweight with a new bolt "2". Install the chain tensioner. Clean the chain with a rag. Make sure that the "arrow" mark on the crankshaft sprocket is at the top.
Install the chain on the crankshaft sprocket, oil pump sprocket and balance shaft sprocket. The marks on the crankshaft sprocket and balance shaft sprocket should be opposite the chain links marked with paint "arrows". The chain links marked with paint are additionally marked with a groove. Install the freewheel sprocket on the chain and screw the sprocket to the crankshaft frame. Remove the locking pin from the chain tensioner.
Make sure that the marks on the crankshaft sprocket and balance shaft sprocket are opposite the chain links marked with paint "arrows". Install the front sealing flange. Install the oil separator with a new sealing ring. Install the oil pan. Install the toothed belt (adjust valve timing). Install the poly V-belt.
Tightening torques:
- Crankshaft frame with counterweight 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)
- Freewheel sprocket to crankshaft frame: 20 Nm
- Oil separator to crankshaft frame: 5 Nm
1) Replace the bolt