Upper Timing Chain - Remove For Access (G2735404): Installation

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• Install the timing chain.

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• Install the variable valve timing unit.
• Install the bolt, but do not fully tighten at this stage.

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Using a suitable tool, remove and discard the lower timing chain cover blanking plug.

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Make sure the timing chain is located on the idler pulley.

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Make sure a new lower timing chain blanking plug is installed.

Renew Part: Lower timing cover blanking cap Quantity: 1  .

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• CAUTION: If the timing chain is not in this condition, or there is no gap, reposition the timing chain and re-measure.
  NOTE: This step is to make sure the timing chain is in the correct position on the gears.

  Install the previously retained timing chain tensioner and allow it to release fully as illustrated.

• Push the left side of the timing chain towards the cylinder head, there should be a gap between the timing chain and the cylinder head.
• Remove and discard the timing chain tensioner.

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Install the timing chain tensioner guide.

Renew Part: Upper timing chain guide Quantity: 1  .

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Install the special tool.

Special Tool(s): JLR-303-1631 

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• Install and tighten a new variable valve timing unit bolt, using the indicated sequence.

  Renew Part: Variable valve timing unit retaining bolt Quantity: 1  .

  Torque 

  Stage 1: 10 Nm 

  Stage 2: Loosen: 90° 

  Stage 3: 25 Nm 

  Stage 4: 40° 

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Remove the special tool.

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• CAUTION: Only replace the timing chain guide when replacing the timing chain, guides and tensioners as a set.

  Install the timing chain guide.

• Install and tighten the bolt.

  Torque  : 25 Nm 

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Before installing the new timing chain tensioner, make sure that the ratchet clip is on the first groove.

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• Install and tighten a new timing chain tensioner.

  Renew Part: Timing chain tensioner Quantity: 1  .

  Torque  : 55 Nm 

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To correctly deploy the timing chain tensioner, push the timing chain guide against timing chain tensioner in the position illustrated.

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• Remove the bolt.
• Remove the special tool.

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Remove the special tool.

Refer to: UPPER TIMING COVER .

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• Install the charge air cooler bracket,
• Install and tighten the 2 bolts.

  Torque  : 40 Nm 

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• Install the wiring harness.
• Install and tighten the 2 nuts.

  Torque  : 12 Nm 

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• Install the wiring harness.
• Connect the electrical connector.

Refer to: CHARGE AIR COOLER .

Refer to: HOOD - INGENIUM I4 2.0L DIESEL/INGENIUM I4 2.0L PETROL/TDV6 3.0L DIESEL/V6 S/C 3.0L PETROL .

Refer to: SECONDARY BULKHEAD LEFT PANEL - INGENIUM I4 2.0L DIESEL .

Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .