General Procedures - Balance Shaft Backlash

Special Service Tools / General Equipment

	100-002 (TOOL-4201-C) Dial Indicator Holding Fixture
	303-1688 Balance Shaft Preload Tool
	303-507 Timing Pin, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-RYAD

Check

1. 1
   Install the special service tool and slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC position. The engine is now at TDC.
   Use the special service tool: 303-507 Crankshaft TDC Pin.

   

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

   

3. 3
   Remove the bolts and the oil outlet tube.

   

4. 4
   Inspect the outlet oil tube O-rings and replace if damaged.

   

5. 5
   1. Remove the bolt securing the oil supply tube to the bracket.

   2. Remove the bolt and the oil supply tube bracket.

   3. Remove the bolts and the oil supply tube.

   

6. 6
   Inspect the inlet oil tube O-rings and replace if damaged.

   

7. 7
   Remove the bolts and the balance shaft module.

   

8. 8
   Remove the shims from the balance shaft housing mating surfaces.

   

9. 9
   1. Visually inspect the balance shaft module gear for damage.

   2. Make sure the shaft rotates smoothly.

   • If damaged or faulty, replace the balance shaft module.

   

10. 10
    Install the No. 50 main shims onto the balance shaft module mounting surfaces.

    

11. 11
    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.

    

12. 12
    Install the bolts and tighten in the sequence shown.
    Torque:
    Stage 1: 27 lb-ft (36 N·m)
    Stage 2: 60 degrees

    

13. 13
    Loosen the bolts.

    

14. 14
    Tighten the bolts in the sequence shown.
    Torque:
    Stage 1: 133 lb-in (15 N·m)
    Stage 2: 45 degrees

    

15. 15
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

16. 16
    Rotate the crankshaft to make sure there is no binding between the balance shaft gear and the crankshaft gear.

    

17. 17
    Install the special service tool and slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC position. The engine is now at TDC.
    Use the special service tool: 303-507 Crankshaft TDC Pin.

    

18. 18
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

19. 19
    • Install the 5 mm hex key and tighten the worm clamp as shown.

    • Mark the hex key with a 20 mm (0.79 inch) file mark above the top surface of the driven gear.

    • Install the balance shaft preload tool and bolts as shown.
      Use the special service tool: 303-1688 Balance Shaft Preload Tool.

    • Install and position the dial indicator with holding fixture on the 20 mm (0.79 inch) hex key as shown.
      Use the special service tool: 100-002 (TOOL-4201-C) Dial Indicator Holding Fixture.

    • 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.

    

20. 20
    Using the backlash measurement, select the correct shims from the Shim Selection Chart.
    

    1. Play

    2. Selective Shim (No.)

    3. Shim Thickness

    

21. 21
    Remove the bolts and the balance shaft module.

    

22. 22
    Remove the No. 50 main shims from the balance shaft module.

    

23. 23
    Install the selected shims onto the balance shaft module mounting surfaces as specified in the table above.

    

24. 24
    Install the special service tool and slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC position. The engine is now at TDC.
    Use the special service tool: 303-507 Crankshaft TDC Pin.

    

25. 25
    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.

    

26. 26
    Install the bolts and tighten in the sequence shown.
    Torque:
    Stage 1: 133 lb-in (15 N·m)
    Stage 2: 45 degrees

    

27. 27
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

28. 28
    • Install the 5 mm hex key and tighten the worm clamp as shown.

    • Mark the hex key with a 20 mm (0.79 inch) file mark above the top surface of the driven gear.

    • Install the balance shaft preload tool and bolts as shown.
      Use the special service tool: 303-1688 Balance Shaft Preload Tool.

    • Install and position the dial indicator with holding fixture on the 20 mm (0.79 inch) hex key as shown.
      Use the special service tool: 100-002 (TOOL-4201-C) Dial Indicator Holding Fixture.

    • 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 backlash exceeds the specified range of 0.040 to 0.140 mm (0.00157 to 0.0055 inch), install a new balance shaft module and repeat the procedure.

    

29. 29
    Lubricate the inlet oil tube O-rings with clean engine oil.

    

30. 30
    1. Install the oil supply tube and bolts.
       Torque: 97 lb-in (11 N·m)

    2. Install the oil supply tube bracket and bolt.
       Torque: 97 lb-in (11 N·m)

    3. Install the bolt securing the oil supply tube to the bracket.
       Torque: 97 lb-in (11 N·m)

    

31. 31
    Lubricate the outlet oil tube O-rings with clean engine oil.

    

32. 32
    Install the oil outlet tube and bolts.
    Torque: 97 lb-in (11 N·m)