General Procedures - Balance Shaft Backlash

Special Service Tools / General Equipment

	100-002 (TOOL-4201-C) Dial Indicator Holding Fixture
	303-507 Timing Pin, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-RYAD

Check

1. 1
   • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

   • Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC timing pin. The engine is now at TDC.

   

2. 2
   Mark the balance shaft housing and shafts from the top to make sure the balance shaft housing is at TDC.

   

3. 3

   

4. 4
   Remove the shims from the balance shaft housing mating surfaces.
5. 5
   Install the main shims (No. 50) onto the balance shaft housing mating surfaces.
6. 6
   With the balance shaft marks at TDC, slowly install the balance shaft housing onto the cylinder block, taking care to avoid contact between the crankshaft drive gear and the balance shaft driven gear.

   

7. 7
   Torque:
   Stage 1: 18 lb-ft (25 N·m)
   Stage 2: 38 lb-ft (52 N·m)

   

8. 8
   • Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

   • Rotate the crankshaft to make sure there is no binding between the balance shaft gear and the crankshaft gear.

   

9. 9
   • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

   • Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC timing pin. The engine is now at TDC.

   • Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

   

10. 10
    • Position as shown. Measure the gear backlash.
      Use Special Service Tool: 100-002 (TOOL-4201-C) Dial Indicator Holding Fixture.

    • Position the dial indicator, holding the Holder (1) on the hex key 80 mm (3.149 in) above the driven gear shaft center (2) on the balance shaft housing.

    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.

    

11. 11
    Using the backlash measurement, select the correct shims from the Shim Selection Chart.
    

    1. Play

    2. Selective Shim (No.)

    3. Shim Thickness

    

12. 12
    • Remove the balance shaft module from the cylinder block.

    • Install the selected shims onto the balance shaft module mounting surfaces.
13. 13
    • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

    • Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC timing pin. The engine is now at TDC.

    

14. 14
    With the balance shaft marks at TDC, slowly install the balance shaft housing onto the cylinder block, taking care to avoid contact between the crankshaft drive gear and the balance shaft driven gear.

    

15. 15
    Torque:
    Stage 1: 18 lb-ft (25 N·m)
    Stage 2: 38 lb-ft (52 N·m)

    

16. 16
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

17. 17
    • Position as shown. Measure the gear backlash.
      Use Special Service Tool: 100-002 (TOOL-4201-C) Dial Indicator Holding Fixture.

    • Position the dial indicator, holding the Holder (1) on the hex key 80 mm (3.149 in) above the driven gear shaft center (2) on the balance shaft housing.

    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.

    • If the play exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balance shaft module and repeat the procedure.