Balance Shaft Chain: Service and Repair

- TOOLS REQUIRED
- J-38122 Crankshaft Pulley Holder
- SA9105E Engine Support Fixture
- J-43405 Engine Support Fixture Adapter

REMOVAL





1. Disconnect negative battery cable.
2. Remove front cover. (Refer to "Front Cover and Oil Pump Assembly Removal".)





3. Remove camshaft cover assembly. (Refer to "Camshaft Cover Removal".)





4. Remove timing chain (Refer to "Timing Chain Removal".)





5. Remove balance shaft drive chain tensioner.





6. Remove adjustable balance shaft chain guide.





7. Remove small balance shaft chain guide.





8. Remove upper balance shaft chain guide.

NOTICE: Push on chain between water pump and crankshaft sprockets so that all slack is between these two points. This will allow easier removal of chain.





9. Remove balance shaft drive chain
10. Remove crankshaft drive sprocket.

NOTICE: Replace balance shaft drive chain guide if wear exceeds 1.12 mm (0.045 inch).





11. Inspect balance shaft drive chain guides for cracking or wear.

NOTICE: Replace balance shaft drive chain tensioner shoe if wear exceeds 1.12 mm (0.045 inch).

12. Inspect balance shaft drive chain tensioner shoe for excessive wear.
13. Inspect balance shaft drive chain and sprockets for wear.
14. Inspect camshaft sprocket faces for signs of movement.
15. Inspect alignment notch in camshaft for cracking or damage.
16. Inspect water pump, crankshaft, and balance shaft sprocket teeth and chain for signs of excessive wear chipping, or seizure of balance shaft drive chain links.

INSTALLATION

IMPORTANT: If balance shafts are not correctly timed to crankshaft the engine may vibrate or make excessive noise.





1. Orient the timing marks on the balance shafts.
a. The intake side balance shaft timing mark should be pointing up.
b. The exhaust side balance shaft timing mark should be pointing down.
2. With balance shafts oriented, install balance shaft crankcase sprocket onto crankshaft.
3. Place number one piston at top dead center (TDC).

NOTICE: The crankshaft keyway slot will be pointing up (12 o'clock position) when set at TDC.





4. Install balance shaft chain with colored links lined up with marks on balance shaft sprockets with mark on crankshaft sprocket.

IMPORTANT: There is one (1) copper link and two (2) chrome links on balance shaft chain.

a. Orient chain so that copper (1) and chrome (2) links are visible.
b. Place copper colored link (1) onto timing mark on intake side balance shaft sprocket.
c. Working clockwise along chain place first chrome link in line with timing mark on crankshaft sprocket.
d. Align last chrome link with timing mark on exhaust side balance shaft sprocket.





5. Install upper chain guide and bolt.





6. Install small chain guide and bolt.
7. Tighten chain guide bolt.
- Torque: 10 Nm (89 inch lbs.)





8. Install adjustable chain guide and bolts.
- Torque: 10 Nm (89 inch lbs.)





9. Rotate plunger on chain tensioner 30 degrees and compress plunger and lock in place by inserting a thin wire (or paper clip) into the hole on side of plunger body.
10. Install chain tensioner and bolts.
11. Tighten chain tensioner bolts.
- Torque: 10 Nm (89 inch lbs.)
12. Remove thin wire (or paper clip) from chain tensioner to release plunger.





13. Install timing chain (Refer to "Timing Chain Installation".)





14. Install camshaft cover. (Refer to "Camshaft Cover Installation".)





15. Install front cover. (Refer to "Front Cover and Oil Pump Assembly Installation".)
16. Connect negative battery cable.