Subject:
Supplement to Service Instructions and Labour Times Guide.
Vehicles:
Sintra with X 22 XE DOHC Petrol Engine.
The following operations are not included in the published Sintra Service Instructions, date of edition 9 / 96, KTA - 1865 -...: "Tooth Backlash, Balancer Shaft Unit / Crankshaft, Check" and "Tooth Backlash, Balancer Shaft Unit / Crankshaft, Adjust".
These operations will be included in the next revision of the Service Instructions and Labour Time Guide.
Tooth Backlash, Balancer Shaft Unit / Crankshaft, Check
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
|---|
Remove wiper motor, front axle body and oil pan - see corresponding operation in the Service Instructions.
Detach oil intake pipe (1) from oil pump and balancer shaft unit. Detach oil baffle plate (2) from balancer shaft unit.
| .D. ICON08.tif | 0,75 | 0,75 | tiff;; Adjust |
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At fastening bolt of toothed belt drive gear, turn crankshaft in engine rotational direction to mark (3) 1 st cylinder "TDC".
| In this crankshaft position, the flattened sides (arrows) of both balancer shafts must face downward and must be on a horizontal line. | |||
|---|---|---|---|
| .P. G0163.tif | 9 | 16 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Screw Measuring Device KM - 949 (3) with long knurled bolt (1) into 1 st balancer shaft (intake side) and tighten hand - tight - measuring arm (5) must point in "9 o'clock" direction.
Screw short knurled bolt (2) into 2nd balancer shaft (exhaust side) and tighten likewise hand - tight.
Install dial gauge holder with Dial Gauge KM - 798 (4) on cylinder block and place pre - tensioned probe (6) of gauge on measuring arm of Measuring Device KM - 949. The probe must be set precisely between the notch marks, square to the plane surface (7).
| Determine the left and right stops by turning the knurled bolt (2) to and fro. Set the dial of the gauge to zero. | |||
|---|---|---|---|
| .P. G0164.tif | 9 | 16 | tiff;; |
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Use the knurled bolt (1) to move the 2nd balancer shatt (exhaust side) to and fro again - simultaneously read off the tooth backlash trorn the gauge.
The permissible tooth backlash is: 0.02 mm to 0.06°mm / 0. 0008 to 0. 0024 in.
The tooth backlash must be measured in 4 ditferent positions - turn the crankshaft further at the fastening bolt of the toothed belt drive gear by 45° in the engine rotational direction until the measuring arm (2) is at "6 o'clock".
Then loosen the knurled bolt (3), fix the measuring arm at "9 o'clock" again and repeat the measurement.
| If the value determined in one of the 4 measurements lies outside the tolerance (0.02 mm to 0.06 mm / 0.0008 to 0 0024 in.), the tooth backlash must be adjusted. | |||
|---|---|---|---|
| .P. G0165.tif | 9 | 16 | tiff;; |
Tooth Backlash, Balancer Shaft Unit / Crankshaft, Adjust
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
|---|
Detach balancer shaft unit from cylinder block / crankshaft bearing caps and remove with balancer piece. The balancer piece has a number (code), for easy assignment. The tooth backlash can be adjusted by using a balancer piece with a different thickness.
| Code | Thickness of balancer piece in mm | Part no. | Catalogue no. |
|---|---|---|---|
| 55 | 0.535 to 0.565 | 90 571 078 | 6 84 979 |
| 58 | 0.565 to 0.595 | 90 571 079 | 6°84°980 |
| 61 | 0.595 to 0.625 | 90 571 080 | 6°84°981 |
| 64 | 0.625 to 0.655 | 90 571 081 | 6 84 982 |
| 67 | 0.655 to 0.685 | 90 571 082 | 6 84 983 |
| 70 | 0.685 to 0.715 | 90 571 083 | 6 84 984 |
| 73 | 0.715 to 0.745 | 90 571 084 | 6 84 985 |
| 76 | 0.745 to 0.775 | 90 571 085 | 6 84 986 |
| 79 | 0.775 to 0.805 | 90 571 086 | 6 84 987 |
| 82 | 0.805 to 0.835 | 90 571 087 | 6 84 988 |
| 85 | 0.835 to 0.865 | 90 571 088 | 6 84 989 |
Note:
The next larger or smaller balancer alters the tooth backlash by 0.02 mm / 0.0008 in.
Example of selection of balancer piece: The installed balancer piece with the code "70" gave a tooth backlash of 0.08 mm / 0.0031 in. If a balancer piece with the code "67" is now installed, the tooth backlash will be approx. 0.06 mm / 0.0024 in.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
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Only one balancer piece may be installed.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
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At fastening bolt of toothed belt drive gear, turn crankshaft in engine rotational direction to mark (1) 1 st cylinder "TDC".
Turn balancer shafts until the flattened sides (arrows) of both balancer shafts face downward and are on a horizontal line.
Attach selected balancer piece (2) with balancer shaft unit to cylinder block / crankshaft bearing cap - tighten all fastening bolts uniformly - tightening torque 20 Nm / 15 Ibf. ft.
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
|---|
After installing the balancer shaft unit, recheck the tooth backlash and readjust if necessary.
Note:
| If the balancer shaft unit has to be replaced, use the thickest balancer piece with the code "85" for the initial assembly - this guarantees tooth backlash in all conditions. | |||
|---|---|---|---|
| .P. G0166.tif | 9 | 16 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Attach oil intake pipe to oil pump with new seal ring and insert fastening bolts with locking agent - tightening torque 8 Nm / 6 Ibf. ft. Attach oil intake bracket to balancer shaft unit -°tightening torque 20 Nm / 15 Ibf. ft.
Install oil pan, front axle body and wiper motor - see corresponding operation in Service Instructions.
Time Allowance:
J 3209 00 Balancer Shaft Backlash - Check 5.3 hrs
TC: 26, 36, 40
Add:
001 Adjust balancer shaft backlash . 9 hrs
J 3210 00 Balancer Shaft Unit - Remove and Reinstall / Replace 5.5 hrs
TC: 01, 04, 15, 34
Add:
001 Adjust balancer shaft backlash 1.2 hrs
W 1000 00 Vehicle from Parking Place to Workplace and Back . 2 hrs
TC: 99
The regular warranty procedure should be used for claiming set - up time.