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

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

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- Install the timing chain.
CAUTION:
- Make sure the highlighted links on the timing chain are in line with the timing marks as illustrated.
- Make sure the camshaft pin is located in the variable valve timing unit correctly.
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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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- Install the previously retained timing chain tensioner and allow it to release fully as illustrated.
  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.
- 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.
CAUTION: Only replace the timing chain guide when replacing the timing chain, guides and tensioners as a set.

NOTE: If the timing chain tensioner guide can not be installed repeat step 6.

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Install the timing chain tensioner guide.

Renew Part: Upper timing chain guide Quantity: 1 .
CAUTION: Use 2 suitable M6 X 20 bolts to install the special tool to the cylinder head.

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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 2Loosen: 90°
  
  Stage 3: 25 Nm
  
  Stage 4: 40°
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Remove the special tool.
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- Install the timing chain guide.
  CAUTION: Only replace the timing chain guide when replacing the timing chain, guides and tensioners as a set.
- 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
CAUTION:
- Do not directly touch the timing chain tensioner at this stage.
- Make sure the timing chain tensioner is fully deployed.
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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.
Install the upper timing cover.
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.
Install the charge air cooler.
Refer to: CHARGE AIR COOLER
Install the hood.
Refer to: HOOD
Install the secondary bulkhead panel.
Refer to: SECONDARY BULKHEAD LEFT PANEL - INGENIUM I4 2.0L DIESEL
Connect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT