Balance Shaft Assembly (G3187030): 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  67 -  77 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.

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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 

    Stage 1: 37 Nm 

    Stage 2: 90° 

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    Tighten the 12 engine front cover bolts.

    Torque  : 12 Nm 

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    • Install the lower timing chain left 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 lower timing chain right 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  : 25 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 8 bolts.

    Torque 

    M8x35 Hex Bolts: 25 Nm 

    M8x30 Torx® Bolts: 25 Nm 

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    • Install and tighten the 3 lower timing cover upper bolts.

      Torque  : 12 Nm 

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    • Install the special tool to the end of the crankshaft.

      Special Tool(s): JLR-303-1674A 

    • Install and hand-tighten the 2 bolts.
38. CAUTION: Make sure that the mating face is clean and free of foreign material.
    NOTE: The component labelled B  in the illustration is an alignment spacer provided with the new seal.

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    • Position the new crankshaft rear oil seal A  and spacer B  as illustrated.

      Renew Part: Crankshaft rear seal Quantity: 1  .

    • Carefully install the crankshaft rear oil seal A  over the end of the crankshaft and discard the spacer.

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    • Install the second part of special tool JLR-303-1674A to position the crankshaft oil seal correctly
    • Tighten the bolt until the seal is fully installed and the bolt stops turning.

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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 

42. Fig 1: Flywheel Bolts Tightening Sequence

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    • With the aid of another technician, install the flywheel.
    • Install and tighten the 8 bolts in the sequence illustrated.

      Renew Part: Dual mass flywheel bolts. Quantity: 8  .

      Torque 

      Stage 1: 30 Nm 

      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 

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    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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    • With the aid of another technician, install the drive plate.
    • Install and tighten the 8 bolts in the sequence illustrated.

      Renew Part: Drive plate bolts Quantity: 8  .

      Torque 

      Stage 1: 30 Nm 

      Stage 2: 120° 

    The following step(s) applies to: 

    All vehicles 

53. Install the CKP  .

    Refer to: Crankshaft Position Sensor REMOVAL AND INSTALLATION .

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    Remove the crankshaft damper pulley holding tool.

    Special Tool(s): JLR-303-1630 

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    • Remove the 2 bolts.
    • Remove the special tool.
56. CAUTION: Make sure that the mating faces are clean and free of foreign material.

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

      Refer to: SPECIFICATIONS

57. CAUTION: Make sure that the mating faces are clean and free of foreign material.

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    Install a new gasket.

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

58. Fig 3: Upper Timing Cover Tightening Sequence

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

      Torque 

      Stage 1: 14 Nm 

      Stage 2: Loosen 180° 

      Stage 3: 14 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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    Install the NVH  pad.

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    • Install the fuel injector pump bracket.
    • Secure the 3 clips.
    • Connect the electrical connector.
    • Install and tighten the 4 bolts.

      Torque  : 12 Nm 

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    • Reposition the exhaust pressure sensor to the original location.
    • Install and tighten the 3 bolts.

      Torque  : 10 Nm 

    • Reposition the 2 coolant hoses to the original location.
    • Secure the coolant hose clip.

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    • Secure the 5 wiring harness clips.
    • Connect the 2 electrical connectors to the 2 VCT  solenoids.
    • Connect the exhaust pressure sensor.
    • Secure the 2 wiring harness clips to the pipe.

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

      Torque  : 10 Nm 

    • Secure the clip.

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

      Torque  : 12 Nm 

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    • Install the 2 coolant hoses to the underside of the coolant separator.
    • Secure the 2 coolant hose clamps and remove the 2 hoses.
    • Secure the bleed line connection.

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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 

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    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 

73. 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 

77. Install the transmission.

    The following step(s) applies to: 

    Vehicles with automatic transmission 

78. Install the transmission.

    Refer to: the appropriate service information .

    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 

82. Vacuum fill the cooling system.

    Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING (G2390776) .

83. Connect the 12 V system.

    Refer to: the appropriate service information .

    The following step(s) applies to: 

    Plug in hybrid electric vehicles only 

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    Power Up the HV  system. Only technicians qualified to EVAP  level are allowed to perform this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the EV  Safety Rules.

    The following step(s) applies to: 

    All vehicles 

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