Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

ENGINE
OVERHAUL19
14.Remove 2 bolts securing engine front lifting
bracket, remove bracket.Valves and springs - remove
1.Support cylinder head clear of valves, use a
hollow drift and tap each valve spring cap to
free collets.
2.Position cylinder head on its side.
3.Using toolLRT-12-034compress valve spring.
4.Remove 2 collets from valve stem.
5.Remove toolLRT-12-034. 

ENGINE
20
OVERHAUL
6.Remove spring cup, valve spring and spring
seat. Keep components in their fitted order.
7.Remove and discard valve stem oil seal.
8.Remove valve, and retain in fitted order.
9.Repeat above procedures for remaining
valves.Cylinder head - inspection
1.Decarbonise cylinder head.
2.Examine cylinder head for cracks, pay
particular attention to area between inlet and
exhaust valve seats. Cracks indicate engine
has overheated and cylinder head must be
replaced.
3.Check core plugs for signs...

ENGINE
OVERHAUL21
Valve springs - inspection
1.Check free length of each spring = 46.28 mm
2.Check that end coils of each spring are square
to body of spring.Valves and guides - inspection
1.Remove carbon from valves.
2.Examine head of each valve for cracks and
burning and valve seat for pitting or burning,
replace valves as necessary.
3.Check valve seating faces for pitting, if light
pitting cannot be removed during valve
grinding operations, valves may be refaced.
CAUTION: If refacing results in valve...

ENGINE
22
OVERHAUL
8.Insert a new valve into each guide in turn and
with head of valve positioned 8.0 mm above
seat insert, measure side to side movement of
valve head using a suitable DTI.
Maximum valve head movement = 0.15 mm
9.Replace any valve guide which permits valve
head movement in excess of the above figure.Valve guides - renew
1.Support cylinder head, combustion face
upwards on blocks of wood.
2.Using toolLRT-12-036,drift valve guide out of
cylinder head, discard guide.
3.Clean valve guide...

ENGINE
OVERHAUL23
5.Position cylinder head on bed of hand press.
6.Position replacement valve guide to cylinder
head, ensuring that groove for valve stem seal
is facing away from cylinder head.
7.Position distance piece, toolLRT-12-515and
valve guide replacerLRT-12-046to valve
guide.
8.Press valve guide into cylinder head until
distance piece contacts face of head; remove
tools.
9.Allow cylinder head to air cool.Valve seat inserts - refacing
CAUTION: Prior to refacing valve seats,
check valve head stand...

ENGINE
24
OVERHAUL
3.Lightly lubricate the tool with engine oil.
4.Insert pilot into valve guide from combustion
chamber side of cylinder head until shoulder of
pilot contacts guide.
5.Check that collet is fully inserted into valve
guide and expand collet against the guide
using a suitable tommy bar.
6.Assemble the 45°cutter,MS621(exhaust
valves) and 60°cutter,MS627(inlet valves) to
toolLRT-12-501.
7.Position toolLRT-12-501and appropriate
cutter to valve seat insert to be refaced.
8.Using the Allen key,...

ENGINE
OVERHAUL25
9.Cut valve seat insert using light hand pressure.
CAUTION: Remove the minimum amount
of material necessary to obtain correct
valve seat face.
10.Smear Prussian Blue to seating face of a
correctly ground valve.
11.Insert valve into guide and press it firmly,
without rotating on to seat insert, remove valve.
12.Check that an even line of Prussian Blue has
been transferred to centre of valve seat insert,
continue cutting operation as necessary until
this has been achieved.
13.Upon...

ENGINE
26
OVERHAUL Lapping-in valves
1.Lap each valve to its seat using grinding paste.
2.Apply Prussian Blue to valve seat insert. Insert
valve into guide and press it firmly, without
rotating on to seat.
3.Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred to valve face, continue lapping-in
valve as necessary.
NOTE: Line does not have to be across
whole width of valve face.
4.Remove all traces of grinding paste on
completion.
5.Check valve head stand down of each...

ENGINE
OVERHAUL27
Valves and springs - refit
1.Lubricate valve stems, guides, spring seats,
valve springs, spring cups and collets with
engine oil.
2.Lubricate new valve stem oil seals with engine
oil and fit to valve guides.
3.Fit spring seat, insert valve into its respective
guide, fit valve spring and spring cup.
4.Compress valve spring using toolLRT-12-034
and fit collets.
5.Remove toolLRT-12-034.
6.Tap spring cup with a soft mallet to ensure that
collets are correctly seated.
7.Repeat above...

ENGINE
28
OVERHAUL 6.From all of the readings obtained, determine
highest protrusion figure and select the
appropriate cylinder head gasket.
Protrusion 0.50 to 0.60 mm - select gasket with
1 identification hole.
Protrusion 0.61 to 0.70 mm - select gasket with
2 identification holes.
Protrusion 0.71 to 0.80 mm - select gasket with
3 identification holes.
Protrusion 0.81 to 0.90 mm - select gasket with
0 identification holes.
NOTE: Identification holes are located on
the edge of the gasket.
7.Remove DTI....