Balance Shaft Assembly (G2244462): Installation

The following step(s) applies to: 

All vehicles

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   Lubricate the new balance shaft with clean engine oil.

   Refer to: SPECIFICATIONS 

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   Carefully install the new balance shaft on to the guide, make sure the balance shaft is supported at all times.

3. CAUTION: Care must be taken to avoid damaging the balance shaft roller bearings in the positions indicated during the installation.

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   Supporting the guide and the balance shaft, carefully slide the complete assembly through the engine.

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   Install the balance shaft alignment tool through the support plate, make sure the tool is installed correctly into the balance shaft holes (1).

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   Install the alignment tool bolt finger tight.

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   Remove the guide tool from the balance shaft.

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   Remove the balance shaft retaining tool extension.

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   Remove the balance shaft gear retaining tool.

9. CAUTION: Make sure the bolt is clean and free from any oil before installation.

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   Install the balance shaft bolt and washer.

   Torque  : 55Nm 

10. Repeat steps  26-38 of the removal procedure for the right side balance shaft.
11. Repeat steps  1-9 of the installation procedure for the right side balance shaft.

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    Remove the balance shaft alignment tools.

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    Remove the end plate bolts.

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    Remove the end plate.

15. Install the lower timing cover.

    Refer to: LOWER TIMING COVER SEALING 

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    Install the bolt in the upper timing cover.

    Torque  : 13Nm 

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    Install the bracket bolt.

    Torque  : 25Nm 

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    Install the coolant pipe.

    Torque  : 12Nm 

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    Connect the coolant hoses.

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    Install the coolant hose.

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    Connect the CKP  electrical harness.

22. CAUTION:

    1. Inspect the front cover and replace if necessary.
    2. Make sure that the surface of the front cover and the engine is clean and free of foreign material.
    3. Steps 30-33 must be completed within 7 minutes of starting to apply the RTV.

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    Apply RTV sealant in the position shown.

    Refer to: SPECIFICATIONS 

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    1. Install the engine front cover.
    2. Use the alignment tool to align the front cover.

       Special Tool(s): JLR-303-1672 

24. NOTE: Do not fully tighten the bolts at this stage.

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    Install and finger tighten the 4 bolts.

25. CAUTION: Continuous forward pressure must be applied on the tool.

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    Fully tighten the 4 bolts in the sequence illustrated

    Torque  : 12Nm 

26. CAUTION: This step must be completed within 40 minutes of starting to apply the RTV.

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    Install and tighten the 8 bolts.

    Torque  : 12Nm 

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    Remove the front cover alignment tool.

    Special Tool(s): JLR-303-1672 

28. CAUTION: This step is only required if the front cover is re-used.

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    1. Install the special tool.

       Special Tool(s): JLR-303-1628 

    2. Rotate the special tool and the crankshaft front seal 35° in a counter clockwise direction.
    3. Remove the special tool and the crankshaft front seal.
    4. Remove and discard the crankshaft front seal.
29. CAUTION: This step is only required if the front cover is re-used.

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    1. Install a new crankshaft front seal to the special tool.

       Special Tool(s): JLR-303-1628 

       Renew Part: Crankshaft front oil seal  Quantity: 1  .

    2. Install the special tool and the crankshaft front seal.
    3. Rotate the crankshaft front seal and special tool 35° in a clockwise direction.
    4. Remove the special tool.
30. NOTE:

    1. Make sure that the mating faces are clean and free from foreign material.
    2. Install crankshaft damper onto guide pin for correct installation.

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    Install the crankshaft damper locking tool and damper.

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    Before installing the new crankshaft damper bolts check the length of the thread as shown in the illustration. The new bolts must be 48mm in length.

    Renew Part: Crankshaft pulley bolt  Quantity: 4  .

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    Install the crankshaft damper bolts and tighten in a diagonal sequence.

    Torque 

    Stage 1: 37Nm 

    Stage 2: 90° 

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    Install the accessory drive belt tensioner.

    Torque  : 47Nm 

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    Install the left side idler pulley.

    Torque  : 48Nm 

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    Install the upper idler pulley.

    Torque  : 25Nm 

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    1. Using a M10 x 1.0mm bottoming tap, clean the threads in the end of the crankshaft.
    2. Using suitable brake cleaner, remove any foreign material from the threads.

    The following step(s) applies to: 

    Vehicles with manual transmission

37. WARNING: This step requires the aid of another technician.
    CAUTION:

    1. Make sure that the mating faces are clean and free of foreign material.
    2. Make sure that new bolts are installed.
    3. Tighten the bolts in the sequence shown.
    Fig 1: Flywheel Tightening Sequence

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    Install the flywheel.

    Renew Part: Flywheel bolts  Quantity: 8  .

    Torque 

    Stage 1: 30Nm 

    Stage 2: 120° 

38. NOTE: Using a suitable tool make sure the clutch assembly is installed in the released state.
    Fig 2: Clutch Assembly Tightening Sequence

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    1. Install new bolts.

       Renew Part: Clutch cover assembly bolt(s)  Quantity: 6  .

    2. Follow the indicated sequence and tighten the bolts of the clutch pressure plate each two turns at a time until the specified tightening torque is achieved.

       Torque  : 29Nm 

    The following step(s) applies to: 

    Vehicles with automatic transmission

39. WARNING: This step requires the aid of another technician.
    CAUTION:

    1. Make sure that the mating faces are clean and free of foreign material.
    2. Make sure that new bolts are installed.
    3. Tighten the bolts in the sequence shown.
    Fig 3: Flexplate Bolts Tightening Sequence

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    Install the drive plate.

    Renew Part: Flexplate bolts  Quantity: 8  .

    Torque 

    Stage 1: 30Nm 

    Stage 2: 120° 

    The following step(s) applies to: 

    All vehicles

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    Remove the crankshaft damper holding tool.

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    Insert a suitable tool, where illustrated, to prevent tension being applied to the accessory belt.

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    Install the accessory drive belt.

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    Tension the accessory drive belt by slowly releasing the tensioner.

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    Remove the engine brace from the vehicle.

    Install the Special Tool(s): JLR-303-1633-01, JLR-303-1692, JLR-303-1692-01 

45. Install the transmission.

    Refer to: TRANSMISSION - INGENIUM I4 2.0L DIESEL

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    Install the charge air cooler mounting bracket.

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    1. Install the charge air cooler mounting bracket nuts.
    2. Install the wiring harness clip.

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    1. Install the 2 wiring harness clips.
    2. Connect the electrical connector.

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    Install the charge air cooler.

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    Install the charge air cooler inlet pipe.

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    1. Install the charge air cooler retaining bolts.
    2. install the throttle body inlet pipe clamp.
52. Install the coolant module.

    Refer to: COOLING MODULE

53. Install the front bumper.

    Refer to: FRONT BUMPER

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    Before installing the oil filter and cap, check the by-pass valve (A) is installed and correctly secured on the locating tabs (B).

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    1. Install a new O-ring seal.

       Renew Part: Oil filter O-ring seal(s)  Quantity: 1  .

    2. Install a new oil filter element.

       Renew Part: Oil filter  Quantity: 1  .

    3. Lubricate the oil filter O-ring seal (A) with clean engine oil and install the oil filter into the cap. Make sure the oil filter is pushed correctly on to the by-pass valve inside the oil filter cap (B).

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    Install the oil filter cap.

    Torque  : 28Nm 

57. 1. Fill the engine with clean engine oil.

       Refer to: SPECIFICATIONS 

    2. Start the engine and allow to run for 10 minutes, stop the engine.
    3. Check for leaks.