Balance Shaft Assembly (G3187563): Removal

The following step(s) applies to: 

All vehicles 

1. Before completing the balance shaft repair, make sure to have followed the Noise, Vibration and Harshness (NVH) balance shaft test procedure.
2. CAUTION: Failure to follow this step may result in damage to the crankshaft rear oil seal.

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   The existing special tool JLR-303-1674 must be modified as illustrated before use.

   Special Tool(s): JLR-303-1674A 

3. Raise and support the vehicle on a suitable 2 post lift.

   Refer to: JACKING .

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   Remove and discard the 2 bolts.

5. NOTE: Apply grease to the shoulder of the special tools to aid operation.

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   Install and hand tighten the 2 special tool bolts.

   Special Tool(s): JLR-303-1711 

   The following step(s) applies to: 

   Vehicles with manual transmission 

6. Remove the transmission.

   Refer to: TRANSMISSION (G2312116)

7. Remove the transmission.

   Refer to: TRANSMISSION (G2312116)

   The following step(s) applies to: 

   Vehicles with automatic transmission 

8. Remove the transmission.

   Refer to: TRANSMISSION - INGENIUM I4 2.0L PETROL (G2317396)

   The following step(s) applies to: 

   All vehicles 

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   • Loosen the element cover 4 complete turns to allow engine oil to drain from the filter cover.
   • Make sure that the O-ring seal is exposed.
   • Allow 10 minutes for the oil to drain from the oil filter housing.

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    • Remove and discard the oil filter element.
    • Remove and discard the O-ring seal.
11. WARNING: Observe due care when draining engine oil as the oil can be very hot.
    CAUTION: Be prepared to collect escaping oil.

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    • Remove and discard the engine oil pan drain plug.
    • Drain the engine oil into a suitable container.
12. Install a new oil pan drain plug.

    Renew Part: Oil pan drain plug Quantity: 1 . 

    Torque  : 23 Nm 

    The following step(s) applies to: 

    Mild Hybrid Electric Vehicles 

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    • Release the Belt Integrated Starter Generator (BISG) belt tensioner.
    • Install the BISG  tensioner locking tool.

      Special Tool(s): JLR-303-1669 

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    • Remove the 3 bolts.
    • Remove the BISG  tensioner.

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    Remove the BISG  belt.

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    Install the special tool to the position illustrated.

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

17. NOTE: The crankshaft may require rotating to the correct position before the special tool can be installed.

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    Install the special tool to the crankshaft damper pulley. Make sure the central hub is located correctly.

    The following step(s) applies to: 

    Non-Mild Hybrid Electric Vehicles 

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    • Release the accessory drive belt tensioner.
    • Install a suitable tool to lock the accessory drive belt tensioner in the removal position.
    • Remove the accessory drive belt.

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    Install the special tool.

    Special Tool(s): JLR-303-1630 

    The following step(s) applies to: 

    Vehicles with manual transmission 

20. Fig 1: Clutch Assembly Bolts Loosening Sequence

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    • Loosen the 6 bolts 2 turns at a time in the sequence illustrated.
    • Remove the clutch assembly.
    • Discard the 6 bolts.
21. NOTE: This step requires the aid of another technician.

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    • Remove and discard the 8 bolts.
    • With the aid of another technician, remove the flywheel.

    The following step(s) applies to: 

    Vehicles with automatic transmission 

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    • Remove and discard the 8 bolts.
    • Remove the drive plate.

    The following step(s) applies to: 

    All vehicles 

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    Remove and discard the 4 bolts.

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    • Remove the special tool.
    • Remove the crankshaft damper pulley.
25. CAUTION: This step is required to avoid stretching or damaging of the 2 Air Conditioning (A/C) pipes.

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    • Remove the 3 bolts.
    • Reposition the A/C  compressor away from the engine assembly and tie aside.
    • Use suitable cable ties to secure the A/C  compressor onto a suitable location on the cooling module.

      General Equipment: Cable ties 

    The following step(s) applies to: 

    Mild Hybrid Electric Vehicles 

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    • Remove the 14 bolts.
    • Remove the engine front cover.

    The following step(s) applies to: 

    Non-Mild Hybrid Electric Vehicles 

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    • Remove the dust cap.
    • Remove the bolt.
    • Remove the idler pulley.

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    • Remove the dust cap.
    • Remove the bolt.
    • Remove the idler pulley.

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    • Remove the bolt.
    • Remove the accessory drive belt tensioner.

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    • Remove the 12 bolts.
    • Remove the lower front engine cover.

    The following step(s) applies to: 

    All vehicles 

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    • Disconnect the 5 coolant hoses.
    • Release the 2 coolant hose clips.

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    • Remove the 2 bolts.
    • Remove the bracket.

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    • Remove the 2 bolts.
    • Remove the bracket.

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    • Remove the 2 bolts.
    • Release the clip.
    • Remove the coolant pipe.
    • Remove and discard the O-ring seals.

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    • Disconnect the 2 electrical connectors.
    • Release the 5 wiring harness clips.
    • Reposition the wiring harness.

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    • Remove the 4 bolts.
    • Remove the 2 Variable Camshaft Timing (VCT) solenoids.
    • Remove and discard the 2 O-ring seals.

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    • Remove the 12 bolts.
    • Remove the upper timing cover.

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    Remove and discard the gasket.

39. NOTE: The crankshaft may require rotating to the correct position before the special tool can be installed.

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    • Install the special tool.

      Special Tool(s): JLR-303-1635 

    • Install and tighten the 2 bolts.

      Torque  : 13 Nm 

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    Make sure the powertrain assembly is supported by the special tool at all times.

    Special Tool(s): JLR-303-1692  , JLR-303-1692-01  , JLR-303-1633 

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    Remove and discard the 2 bolts.

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    Lower the powertrain assembly until it is supported by the special tools as illustrated.

43. CAUTION: Make sure the balance shafts can be removed without any obstructions.

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    Make sure the powertrain assembly is lowered as illustrated.

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    Disconnect the electrical connector.

45. CAUTION: Note the position of the bolts prior to removal.

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    Remove the 2 bolts.

46. CAUTION: Note the position of the bolts prior to removal.

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    • Remove the 13 bolts.
    • Remove the lower timing cover.

    The following step(s) applies to: 

    Mild Hybrid Electric Vehicles 

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

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

    • Install and tighten the 4 bolts removed in step 23.

      Torque  : 25 Nm 

    The following step(s) applies to: 

    Non-Mild Hybrid Electric Vehicles 

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

      Special Tool(s): JLR-303-1630 

    • Install and tighten the 4 bolts removed in step 23.

      Torque  : 25 Nm 

    The following step(s) applies to: 

    All vehicles 

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    Paint a mark on the crankshaft, chain link and main bearing as illustrated.

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    • Use a suitable tool to counter the spring force from the tensioner.
    • Remove the 2 bolts.
    • Remove and discard the lower timing chain tensioner.

      Renew Part: Lower timing chain tensioner Quantity: 1 . 

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    • Remove the 2 bolts.
    • Remove and discard the lower timing chain left guide.

      Renew Part: Lower timing chain lower guide Quantity: 1 . 

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    • Remove the bolt.
    • Remove and discard the lower timing chain right guide.

      Renew Part: Lower timing chain lower guide Quantity: 1 . 

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    • Remove and discard the 4 bolts.
    • Remove the special tool.
    • Remove the crankshaft pulley.

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    There should be sufficient slack in the chain to allow the crankshaft to rotate.

55. CAUTION: This step requires the aid of another technician to make sure the timing chain is clear of the crankshaft.

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    • Install the special tool.

      Special Tool(s): JLR-303-1681 

    • Install and hand tighten the 2 bolts.
    • Rotate the crankshaft to align the special tool to the position illustrated.

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    • Install the 4 bolts.
    • Tighten the 6 bolts.

      Torque  : 10 Nm 

57. CAUTION: The balance shaft will only require small movements, do not over rotate.
    NOTE: If the alignment tool will not correctly locate in the rear of the balance shaft, carefully rotate the balance shaft a small amount at the drive plate end of the engine until the alignment tool can be fully installed.

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    Install the balance shaft alignment tool. Rotate the tool carefully to align with the balance shaft hole 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 installed into the end plate until it stops. There will be a gap of approximately 2.5 mm 2  .
    • Install the bolt finger tight.

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    • Remove the bolt.
    • Remove the washer.
60. CAUTION: Install the special tool finger tight only.

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    Carefully install the balance shaft gear retaining tool finger tight.

61. CAUTION: Install the special tool finger tight only.

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    Install the release bolt into the balance shaft gear retaining tool finger tight at this stage.

62. 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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    • Use suitable tools to 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.
63. 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.

65. CAUTION: Do not over tighten the guide.

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    • Install the balance shaft guide through the extension tool.
    • Carefully install the guide into the end of the balance shaft finger tight.

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    Remove the 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 remove the balance shaft.
    • Rotate the balance shaft in the direction illustrated.
    • Remove the balance shaft.