Balance Shaft Assembly (G2244462): Removal

WARNING: This page is about a different variant/trim than selected.

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

The following step(s) applies to:

All vehicles

Before completing the balance shaft repair, make sure to have followed the Noise, Vibration and Harshness (NVH) balance shaft test procedure.
Refer to: NVH BALANCE SHAFT TEST
Remove the front bumper for access.
Refer to: FRONT BUMPER - VEHICLES WITH: CORE SPECIFICATION
Remove the coolant module for access.
Refer to: COOLING MODULE
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- Release the throttle body inlet pipe clamp.
- Remove the charge air cooler retaining bolts.
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- Remove the charge air cooler inlet pipe.
- Inspect the seals. Replace if damaged.
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Remove the charge air cooler.
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- Disconnect the electrical connector.
- Release the 2 wiring harness clips.
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- Release the wiring harness clip.
- Remove the charge air cooler mounting bracket nuts.
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Remove the charge air cooler mounting bracket.
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Insert a suitable tool, where illustrated, to prevent tension being applied to the accessory belt.
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Remove the accessory drive belt.
Remove the transmission for access.
Refer to: TRANSMISSION - INGENIUM I4 2.0L DIESEL
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Install the engine brace to the vehicle.

Install the Special Tool(s): JLR-303-1633-01 , JLR-303-1692 , JLR-303-1692-01
NOTE: Allow 10 minutes for the engine oil to drain from the oil filter housing.

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- Loosen the element cover 4 complete turns to allow engine oil to drain from the filter cap.
- Make sure that the O-ring seal is exposed.
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- Remove and discard the oil filter element.
- Remove and discard the O-ring seal.
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Drain and discard the engine oil.
Install a new oil pan drain plug.
Renew Part: Oil pan drain plug Quantity: 1 .

Torque : 23 Nm
NOTE: The engine may require rotating to the correct position before the special tool can be installed.

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Install special tool JLR-303-1630 to the crankshaft damper. Make sure the central hub is located correctly.

Install the Special Tool(s): JLR-303-1630

The following step(s) applies to:

Vehicles with manual transmission

NOTE:
- Slacken the bolts of the clutch pressure plate each 2 turns at a time in the sequence shown.
- Discard the bolts.
Fig 1: Clutch Pressure Plate Bolts Loosening Sequence
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Remove clutch assembly.
Remove the flywheel.
WARNING: This step requires the aid of another technician.

NOTE: Discard the bolts.

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The following step(s) applies to:

Vehicles with automatic transmission

NOTE: Discard the bolts.

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Remove the drive plate.

The following step(s) applies to:

All vehicles

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Remove 4 crankshaft damper bolts.
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Remove the crankshaft damper locking tool and damper.
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Using the special tool remove and discard the front crankshaft seal.

Install the Special Tool(s): JLR-303-1628
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Remove the upper idler pulley.
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Remove the left side idler pulley.
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Remove the accessory drive belt tensioner.
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Remove the engine front cover.
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Disconnect Crankshaft Position Sensor (CKP) electrical harness.
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Remove the coolant hose.
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Disconnect the coolant hoses.
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Remove the coolant pipe.
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Remove the bolt from the upper timing cover.
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Remove the lower timing cover upper bolts.
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Remove the bracket bolt.
CAUTION:
- Note the position of the bolts, prior to removal.
- Be prepared to collect escaping oil.
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Remove the lower timing cover bolts. Using a suitable tool, remove the lower timing cover.
NOTE: The crankshaft may require rotating to correctly position.

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Install the special tool end plate to the front of the engine, make sure the crankshaft pin aligns correctly.

Special Tool(s): JLR-303-1681
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Loosely install the 2 bolts into the crankshaft, but do not tighten at this stage. A small amount of crankshaft movement may be required in other steps to assist the install of the balance shaft alignment tools.
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Gently rotate the end plate to align with the bolt holes, install the 4 bolts.

Torque : 10 Nm
NOTE: If the alignment tool will not correctly locate in the rear of the balance shaft, carefully rotate the crankshaft a small amount at the drive plate end of the engine until the alignment tool is installed. The crankshaft will only require small movements, do not over rotate.

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Loosely install the balance shaft alignment tool, rotate the tool carefully to align with the balance shaft holes (1).
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Make sure the balance shaft alignment tool and bolt are installed correctly. The alignment tool must touch the end plate with no gap (1). The alignment tool bolt must be screwed into the end plate until it stops, there will be a gap of approximately 2.5 mm (2).
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Remove the balance shaft bolt and washer.
CAUTION: Install the special tool finger tight only.

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Carefully install the balance shaft gear retaining tool, do not tighten at this stage.
CAUTION: Install the special tool finger tight only.

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Install the release bolt into the balance shaft gear retaining tool, do not tighten, install finger tight at this stage.
CAUTION: Do not rotate the bolt without countering the adapter direction, failure to follow this instruction may result in damage to the vehicle.

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Using suitable tools, rotate the release bolt clockwise and the balance shaft gear retaining tool counter clockwise in one action to release the balance shaft from the gear taper (1). Do not continue to rotate the release bolt when the balance shaft has been released from the taper.
CAUTION: The balance shaft gear retainer must remain on the engine.

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Remove the release bolt, but do not remove the balance shaft gear retainer.
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Install the extension tool to the balance shaft gear retainer.
CAUTION: Do not over tighten the guide.

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Install the balance shaft guide through the extension and carefully thread the guide into the end of the balance shaft.
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Remove the alignment tool bolt.
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Supporting points 1 and 2 in the illustration by hand, carefully slide the complete balance shaft assembly through the engine until the alignment tool (2) is free from the end plate.
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Remove the balance shaft alignment tool.
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- Holding the balance shaft end, carefully slide the complete assembly through the engine to install the new balance shaft.
- Rotate the balance shaft and guide in opposite directions to release the balance shaft when installed.