Balance Shaft Assembly (G3187563): Installation

The following step(s) applies to: 

All vehicles 

1. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Lubricate the new balance shaft with clean engine oil.

   Refer to: SPECIFICATIONS .

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.

   Special Tool(s): JLR-303-1681 

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.
   • 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 damage to 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  59 -  69 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.

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    Apply sealant to the positions illustrated.

    Refer to: SPECIFICATIONS .

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    Use the special tool to install the new crankshaft front seal to the engine front cover.

    Special Tool(s): JLR-303-1628 

    Renew Part: Crankshaft front oil seal Quantity: 1 . 

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    • Install the engine front cover.
    • Install the 12 bolts finger tight at this stage.

    The following step(s) applies to: 

    Mild Hybrid Electric Vehicles 

19. CAUTION:

    • Make sure all the mating faces are clean and free from foreign material.
    • The crankshaft will require rotating to align the special tool. Make sure the crankshaft is returned to the correct position.

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

      Special Tool(s): JLR-303-1686  , JLR-303-1630 

    The following step(s) applies to: 

    Non-Mild Hybrid Electric Vehicles 

20. CAUTION:

    • Make sure all the mating faces are clean and free from foreign material.
    • The crankshaft will require rotating to align the special tool. Make sure the crankshaft is returned to the correct position.

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

      Special Tool(s): JLR-303-1630 

    The following step(s) applies to: 

    All vehicles 

21. CAUTION: Make sure the correct length bolts are installed.

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    1. Bolts to be used for Non Mild Hybrid Electric Vehicles only. 
    2. Bolts to be used for Mild Hybrid Electric Vehicles only. 

       Renew Part: Crankshaft pulley bolts Quantity: 4 . 

22. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install and tighten the 4 crankshaft damper pulley bolts.

    Renew Part: Crankshaft mass damper bolt(s) Quantity: 4 . 

    Torque 

    1. Stage 1: 37 Nm 
    2. Stage 2: 90° 

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    Tighten the 12 engine front cover bolts.

    Torque  : 12 Nm 

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    • Install the left lower timing chain guide.
    • Install and tighten the bolt.

      Torque  : 25 Nm 

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    Install and tighten the bolt.

    Torque  : 25 Nm 

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    • Install the right lower timing chain tensioner guide.
    • Install and tighten the bolt.

      Torque  : 11.5 Nm 

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    • Install a new lower timing chain tensioner.

      Renew Part: Lower timing chain tensioner Quantity: 1 . 

    • Install and tighten the 2 bolts.

      Torque  : 11.5 Nm 

28. CAUTION: Failure to follow this instruction may cause damage to the component.

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    Make sure the paint markings are correctly aligned.

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    Remove the retaining pin and release the lower timing chain tensioner.

30. 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.

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    Position the 2 dowels as illustrated.

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

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

    Refer to: SPECIFICATIONS .

33. CAUTION: Take care not to damage the cylinder head gasket when installing the lower timing cover.

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    • Install the lower timing cover.
    • Install and tighten the 2 bolts.

      Torque  : 5 Nm 

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    • Install the 2 additional bolts as illustrated.
    • Tighten the 4 bolts.

      Torque  : 25 Nm 

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    Install and tighten the 11 bolts.

    Torque 

    M8x35 Hex Bolts: 25 Nm 

    M8x30 Torx® Bolts: 25 Nm 

    M6x30 Hex Bolts: 12 Nm 

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

      Special Tool(s): JLR-303-1674A 

    • Install and tighten the 2 M8 bolts.

      Torque  : 10 Nm 

37. 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.
    • Tighten the bolt until the crankshaft rear oil seal is fully installed.

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    Remove the special tools.

    Special Tool(s): JLR-303-1674A 

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    • Use an M10 x 1.0 mm bottoming tap to clean the threads in the end of the crankshaft.

      General Equipment: M10 tap 

    • Use a suitable cleaning solution to remove any foreign material from the threads.

    The following step(s) applies to: 

    Vehicles with manual transmission 

41. Fig 1: Flywheel Bolts Tightening Sequence

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    CAUTION:

    • This step requires the aid of another technician.
    • Make sure that the mating face is clean and free of foreign material.

    With the aid of another technician, install the flywheel.

42. Install and tighten the 8 bolts in the sequence illustrated.

    Renew Part: Dual mass flywheel bolts Quantity: 8 . 

    Torque 

    1. Stage 1: 30 Nm 
    2. Stage 2: 120° 

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    Use a suitable cleaning solution to clean the flywheel surface.

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    Use the special tool to install the clutch assembly.

    General Equipment: Clutch alignment kit JLR-308-943 

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    Install and tighten the 3 locating studs hand tight.

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    Install the special tool over the 3 locating studs as illustrated.

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    Install the 3 locking nuts hand tight.

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    Turn the handle clockwise as illustrated until the clutch assembly is flush with the drive plate mating face.

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    Install and tighten the 3 bolts.

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

    Torque  : 29 Nm 

50. Remove the special tools.

    General Equipment: Clutch alignment kit JLR-308-943 

51. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install and tighten the 3 bolts.

    Torque  : 29 Nm 

    The following step(s) applies to: 

    Vehicles with automatic transmission 

52. Fig 2: Drive Plate Bolts Tightening Sequence

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

    With the aid of another technician, install the drive plate.

53. Install and tighten the 8 bolts in the sequence illustrated.

    Renew Part: Drive plate bolts Quantity: 8 . 

    Torque 

    1. Stage 1: 30 Nm 
    2. Stage 2: 120° 

    The following step(s) applies to: 

    All vehicles 

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    Connect the electrical connector.

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    Remove the crankshaft damper pulley holding tool.

    Special Tool(s): JLR-303-1630 

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    Raise the powertrain into the correct position.

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    Make sure the powertrain upper support insulator is correctly aligned.

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    Install and tighten the 2 new bolts.

    Renew Part: Powertrain upper support insulator to engine bolt(s) Quantity: 2 . 

    Torque 

    1. Stage 1: 48 Nm 
    2. Stage 2: 60° 

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    Remove the 2 special tool bolts.

    Special Tool(s): JLR-303-1711 

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    Install and tighten the 2 new bolts.

    Renew Part: Powertrain upper support insulator to engine bolt(s) Quantity: 2 . 

    Torque 

    1. Stage 1: 48 Nm 
    2. Stage 2: 60° 

61. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Remove the 2 bolts.
    • Remove the special tool.

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    • Apply a continuous 3 mm diameter bead of sealant to the cylinder head in the areas illustrated.

      Refer to: SPECIFICATIONS .

63. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install a new gasket.

    Renew Part: Upper timing chain cover gasket Quantity: 1 . 

64. Fig 3: Upper Timing Cover Bolts Tightening Sequence

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    • Install the upper timing cover.
    • Install and tighten the 12 bolts in the illustrated sequence.

      Torque 

      1. Stage 1: 5 Nm 
      2. Stage 2: 13 Nm 
      3. Stage 3: Loosen 180° 
      4. Stage 4: 13 Nm 

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    Lubricate the VCT  solenoid bores with new engine oil.

    Refer to: SPECIFICATIONS .

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    • Install 2 new O-ring seals.

      Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 . 

    • Install the 2 VCT  solenoids.
    • Install and tighten the 4 bolts.

      Torque  : 9 Nm 

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    • Connect the 2 electrical connectors.
    • Install the 4 wiring harness clips.

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    • Install a new O-ring seal.

      Renew Part: Engine coolant outlet upper O-ring seal Quantity: 1 . 

    • Install the coolant pipe.
    • Install and tighten the 2 bolts.

      Torque  : 11.5 Nm 

    • Install the clip.

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    • Install the bracket.
    • Install and tighten the 2 bolts.

      Torque  : 10 Nm 

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    • Install the bracket.
    • Install and tighten the 2 bolts.

      Torque  : 11.5 Nm 

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    • Connect the 5 coolant hoses.
    • Install the 2 coolant hose clips.

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    • Cut the cable ties to securing the A/C  compressor onto the cooling module.
    • Reposition the A/C  compressor into the correct location.
    • Install and tighten the 3 bolts.

      Torque  : 24 Nm 

    The following step(s) applies to: 

    Mild Hybrid Electric Vehicles 

73. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install and tighten the 2 bolts.

    Torque  : 25 Nm 

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    Install the BISG  belt.

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    • Install the BISG  tensioner.
    • Install and tighten the 3 bolts.

      Torque  : 25 Nm 

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    • Remove the BISG  belt tensioner locking tool.

      Special Tool(s): JLR-303-1669 

    • Slowly release the BISG  belt tensioner.

    The following step(s) applies to: 

    Non-Mild Hybrid Electric Vehicles 

77. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the accessory drive belt tensioner.
    • Install and tighten the bolt.

      Torque  : 47 Nm 

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    • Install the idler pulley.
    • Install and tighten the bolt.

      Torque  : 48 Nm 

    • Install the dust cap.

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    • Install the idler pulley.
    • Install and tighten the bolt.

      Torque  : 25 Nm 

    • Install the dust cap.

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    • Install the accessory drive belt.
    • Remove the tool and release the tension.

    The following step(s) applies to: 

    Vehicles with manual transmission 

81. Install the transmission.

    Refer to: MANUAL TRANSMISSION (G2312117)

82. Install the transmission.

    Refer to: MANUAL TRANSMISSION (G2312117)

    The following step(s) applies to: 

    Vehicles with automatic transmission 

83. Install the transmission.

    Refer to: TRANSMISSION - INGENIUM I4 2.0L PETROL (G2317398)

    The following step(s) applies to: 

    All vehicles 

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    Before installing the oil filter cap, check the by-pass valve (1)  is installed and correctly secured on the locating tabs (2)  .

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    • Install a new O-ring seal.

      Renew Part: Oil filter and O-ring seal kit Quantity: 1 . 

    • Install a new oil filter element.
    • Lubricate the oil filter O-ring seal (1)  with clean engine oil and install the oil filter element into the cap.
    • Make sure the oil filter element is pushed correctly onto the bypass valve inside the oil filter cap (2)  .

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    Install and tighten the oil filter cap.

    Torque  : 28 Nm 

87. Vacuum fill the cooling system.

    Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING (G2298648)

88. Connect the 12 V system.

    Refer to: BATTERY, MOUNTING AND CABLES - VEHICLES WITH: NON-ELECTRIC VEHICLES (G2320137)

89. • Fill the engine with clean  engine oil.
    • Start the engine and allow to run for 10 minutes, stop the engine.
    • Check for leaks.