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  : 55 Nm 

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  : 13 Nm 

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    Install the bracket bolt.

    Torque  : 25 Nm 

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    Install the coolant pipe.

    Torque  : 12 Nm 

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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:

    • 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 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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    • Install the engine front cover.
    • 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  : 12 Nm 

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  : 12 Nm 

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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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    • 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.
29. 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.
30. NOTE:

    • Make sure that the mating faces are clean and free from foreign material.
    • 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: 37 Nm 

    Stage 2: 90° 

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    Install the accessory drive belt tensioner.

    Torque  : 47 Nm 

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    Install the left side idler pulley.

    Torque  : 48 Nm 

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    Install the upper idler pulley.

    Torque  : 25 Nm 

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

The following step(s) applies to: 

Vehicles with manual transmission 

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

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

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   Install the flywheel.

   Renew Part: Flywheel bolts Quantity: 8 . 

   Torque 

   Stage 1: 30 Nm 

   Stage 2: 120° 

2. NOTE: Using a suitable tool make sure the clutch assembly is installed in the released state.

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   • Install new bolts.

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

   • 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  : 29 Nm 

The following step(s) applies to: 

Vehicles with automatic transmission 

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

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

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   Install the drive plate.

   Renew Part: Flexplate bolts Quantity: 8 . 

   Torque 

   Stage 1: 30 Nm 

   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 

6. 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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   • Install the charge air cooler mounting bracket nuts.
   • Install the wiring harness clip.

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   • Install the 2 wiring harness clips.
   • 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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    • Install the charge air cooler retaining bolts.
    • install the throttle body inlet pipe clamp.
13. Install the coolant module.

    Refer to: COOLING MODULE

14. Install the front bumper.

    Refer to: FRONT BUMPER - VEHICLES WITH: CORE SPECIFICATION

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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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    • Install a new O-ring seal.

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

    • Install a new oil filter element.

      Renew Part: Oil filter Quantity: 1 . 

    • 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  : 28 Nm 

18. • Fill the engine with clean  engine oil.

      Refer to: SPECIFICATIONS

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