Balance Shaft Assembly (G3187030): Removal

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

WARNING:

If the vehicle has been powered down, do not power up the vehicle until all the bonding points have been tested.
It is the responsibility of the Electric Vehicle Senior Authorised Person (EVSAP) to make sure they comply with any local legislation for work on High Voltage (HV).
The approved Personal Protective Equipment (PPE) must be worn where indicated within this procedure and not removed unless indicated within a step. All items of PPE must be checked for signs of damage before each use, if damaged, replacement PPE must be obtained before doing this procedure.

NOTE:

All Permit To Work (PTW) documents must be kept for a minimum of 5 years.
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.
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
Raise and support the vehicle on a suitable 2 post lift.
Refer to: JACKING AND LIFTING

The following step(s) applies to:

Plug in hybrid electric vehicles only
WARNING: Jaguar Land Rover (JLR) Electric Vehicle Competent Person (EVCP) trained technicians only.

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This procedure involves work on components associated with the HV system. Only technicians qualified to EVCP level or higher are allowed to do this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the Electric Vehicle (EV) Safety Rules.
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Power Down the HV system. Only technicians qualified to Electric Vehicle Authorised Person (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.
Refer to HV electrical connector operation and inspection document before disconnecting any HV electrical connectors.
The following step(s) applies to:

All vehicles
Remove the coolant module for access.
Refer to: REMOVAL AND INSTALLATION .
Remove the charge air cooler.
Refer to: CHARGE AIR COOLER - INGENIUM I4 2.0L PETROL
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Remove the 2 clips.
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Remove the 3 clips.
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Remove the 2 nuts.
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- Remove the 2 bolts.
- Remove the charge air cooler bracket.
The following step(s) applies to:

Vehicles with manual transmission
Remove the transmission.
The following step(s) applies to:

Vehicles with automatic transmission
Remove the transmission.
Refer to: the appropriate service information .

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.
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.
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
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
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.
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.
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
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
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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
CAUTION: Be prepared to collect escaping coolant.

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- Release the 2 coolant pipes from the underside of the coolant separator.
- Release the coolant pipe from the left side of the oil separator.
CAUTION: Be prepared to collect escaping coolant.

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- Release the 2 coolant pipes from the right side of the coolant separator.
- Release the coolant pipe bracket from the upper timing cover assembly.
CAUTION: Be prepared to collect escaping coolant.

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- Remove the 2 bolts.
- Remove the coolant separator.
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Remove the 3 clips.
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- Remove the 2 bolts.
- Remove the upper wiring harness support bracket.
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- Release the 5 wiring harness clips.
- Disconnect the 2 electrical connectors from the 2 Variable Camshaft Timing (VCT) solenoids.
- Disconnect the exhaust pressure sensor.
- Release the 2 wiring harness clips from the pipe.
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- Remove the 3 bolts.
- Reposition the exhaust pressure sensor.
- Release the coolant hose clip.
- Reposition the 2 coolant hoses.
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- Disconnect the electrical connector.
- Release the 2 clips.
- Remove the 4 bolts.
- Remove the fuel injector pump bracket.
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Remove the NVH pad.
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- Remove the 4 bolts.
- Remove the 2 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.
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): 303-021
Remove the Crankshaft Position Sensor (CKP).
Refer to: REMOVAL AND INSTALLATION .
CAUTION: Note the position of the bolts prior to removal.

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Remove the 2 dowel locating bolts.
CAUTION: Note the position of the bolts prior to removal.

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Remove the 3 lower timing cover upper bolts.
CAUTION: Note the position of the bolts prior to removal.

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- Remove the 7 remaining bolts.
- Remove the 3 Torx 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
- 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 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.
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
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.
CAUTION: Install the special tool finger tight only.

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Carefully install the balance shaft gear retaining tool finger tight.
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.
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.
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 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.