Replacement Engine - Balance Shaft Assembly (G2519814): Connect

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   Lubricate the new balance shaft with clean engine oil.

2. CAUTION: Make sure the balance shaft is supported at all times.

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   Carefully install the new balance shaft onto the guide.

3. CAUTION: Care must be taken to avoid damage to the balance shaft roller bearings in the positions illustrated during the installation process.

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   Supporting the guide and the balance shaft, carefully install the balance shaft assembly.

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   • Install the balance shaft alignment tool through the support plate.

     Special Tool(s): JLR-303-1681 

   • Make sure the tool is installed correctly into the balance shaft hole (1).

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   Install the bolt finger tight.

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   Remove the guide 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 engine oil before installing. Failure to clean the bolt could cause the bolt to be over tightened and damage the balance shaft.

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   Install and tighten the balance shaft bolt and washer.

   Torque  : 55 Nm 

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    • Remove the bolt.
    • Remove the balance shaft alignment tool.
11. Repeat steps  12- 24 of the removal procedure for the right side balance shaft.
12. Repeat steps  1- 10 of the install procedure for the right side balance shaft.

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    Visually inspect the balance shaft positions.

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    Remove the 4 bolts.

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    • Remove the 2 bolts.
    • Remove the end plate.
16. CAUTION: Make sure all the mating faces are clean and free from foreign material.

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    Remove and discard the crankshaft rear oil seal.

17. CAUTION: Make sure the locating dowels are positioned as shown in the illustration. Failure to position the dowels as shown in the illustration may result in engine damage.

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    Using a suitable tool, position the dowels as shown in the illustration.

18. CAUTION:

    • Make sure all the mating faces are clean and free from foreign material.
    • The lower timing cover must be installed within 7 minutes of applying the RTV sealant.

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    Apply a 3 mm diameter bead of sealant to the area illustrated.

    Refer to: SPECIFICATIONS .

19. CAUTION:

    • Take care not to damage the cylinder head gasket when installing the lower timing cover.
    • Make sure the dowels are correctly located.

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    • Install and tighten the 2 lower timing cover bolts.

      Torque  : 25 Nm 

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    • Install and tighten the 4 lower timing cover bolts.

      Torque  : 25 Nm 

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    Install and tighten the remaining 8 bolts.

    Torque 

    M8 x 35 bolts: 25 Nm 

    M8 x 25 bolts: 25 Nm 

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    Install and tighten the bolt.

    Torque  : 25 Nm 

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    Install and tighten the 3 bolts.

    Torque  : 12 Nm 

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    • Install the crankshaft rear oil seal alignment tool as illustrated.

      Special Tool(s): JLR-303-1674 

    • Install and tighten the 2 M8 bolts.

      Torque  : 10 Nm 

25. CAUTION: Make sure that the mating face is clean and free of foreign material.
    NOTE: The component labelled (2) in the illustration is an alignment spacer provided with the new seal.

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    • Position the new crankshaft rear oil seal (1) and spacer (2) as illustrated.

      Renew Part: Crankshaft rear seal Quantity: 1  .

    • Carefully install the crankshaft rear oil seal (1) over the end of the crankshaft and discard the spacer.

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    • Install the special tool as illustrated.

      Special Tool(s): JLR-303-1674 

    • Tighten the bolt until the crankshaft rear oil seal is fully installed.

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    Remove the special tools.

    Special Tool(s): JLR-303-1674 

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    Install and tighten the bolt.

    Torque  : 13 Nm 

29. CAUTION:

    • Inspect the front cover and replace if necessary.
    • Make sure that the surface of the front cover and the engine is clean and free of foreign material.
    • Steps 29-32 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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    • Install the engine front cover.
    • Use the front cover alignment tool to align the front cover.

      Special Tool(s): JLR-303-1672 

31. CAUTION: Do not fully tighten the bolts at this stage.

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    Install and finger tighten the 4 bolts.

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

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    Fully tighten the 4 bolts in the sequence illustrated.

    Torque  : 12 Nm 

33. 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  : 12 Nm 

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    Remove the front cover alignment tool.

    Special Tool(s): JLR-303-1672 

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

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    • Install the special tool.

      Special Tool(s): JLR-303-1628 

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

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

      Special Tool(s): JLR-303-1628 

      Renew Part: Crankshaft front oil seal Quantity: 1  .

    • Install the special tool and the crankshaft front seal.
    • Rotate the crankshaft front seal and special tool 35° in a clockwise direction.
    • Remove the special tool.
37. NOTE: MHEV  vehicles only.

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    Install the 2 bolts.

    Torque  : 25 Nm 

38. CAUTION: Make sure all the mating faces are clean and free from foreign material.

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    • Install the crankshaft damper pulley.
    • Install the special tool.

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    Install and tighten the 4 old  crankshaft damper pulley bolts.

    Torque  : 37 Nm 

40. NOTE: New bolts will be installed in the engine assembly procedure.

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Remove and discard the 4 crankshaft damper pulley bolts.