Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

ENGINE
OVERHAUL59
Crankshaft - regrinding
NOTE: Crankshaft journals may be
reground to the following dimensions.
Main bearing journals = 63.225 to 63.237 mm
Big-end bearing journals = 58.475 to 58.494 mm
CAUTION: Rotation of crankshaft must be
in an ANTI-CLOCKWISE direction when
viewed from flywheel end of crankshaft.
1.Grind journals ensuring that grinding wheel
travels beyond edge of journalAto avoid
formation of a stepB.
CAUTION: Take care not to damage fillet
radius C.
2.Final finishing should be...

ENGINE
60
OVERHAUL Main bearing clearance - checking
CAUTION: If crankshaft has been
reground, oversize main bearing shells
must be fitted.
1.Degrease new main bearing shells and ensure
all traces of oil are removed from crankshaft
journals.
2.Fit new main bearing shells to saddles and
main bearing caps ensuring that tags are
located in recesses in saddles and bearing
caps.
NOTE: Number 5 main bearing shells are
wider than numbers 1 to 4.
3.Using assistance, fit crankshaft.
4.Place a piece of Plastigage...

ENGINE
OVERHAUL61
Crankshaft end-float - checking
1.Lubricate upper main bearing shells and
crankshaft main bearing journals with engine
oil.
2.Lubricate new standard size thrust washers
with engine oil and position washers in recess
in centre main bearing saddle.
NOTE: Grooved side of washers must face
outwards.
3.Using assistance, fit crankshaft.
4.Attach a DTI to rear face of cylinder block with
stylus contacting end of crankshaft; push
crankshaft fully rearwards and zero gauge.
5.Push crankshaft...

ENGINE
62
OVERHAUL Big-end bearing clearance - checking
1.Fit pistons and connecting rods.
2.Degrease new big-end bearing shells.
3.Fit big-end bearing shells to connecting rods
ensuring that tag is located in recess in
connecting rod.
4.Fit big-end bearing shells to bearing caps
ensuring that tag is located in recess in cap.
5.Temporarily fit crankshaft pulley bolt and rotate
crankshaft to bring numbers 1 and 4 journals to
BDC.
6.Remove all traces of oil from crankshaft
journals.
7.Pull numbers 1 and 4...

ENGINE
OVERHAUL63
Crankshaft, main and big-end bearings - refit
Crankshaft and main bearings
CAUTION: Cylinder bores must be
inspected before crankshaft is refitted -
See cylinder block - inspection
1.Lubricate selected main bearing shells, thrust
washers and crankshaft journals with engine
oil, ensure bolt holes in bearing saddles are
clean and dry; fit bearing shells in main bearing
caps and saddles.
2.Fit seal guidesLRT-12-035to cylinder block
ensuring that edges of guides are parallel to
edge of main...

ENGINE
64
OVERHAUL 8.Tighten centre main bearing cap bolts to 133
Nm.
9.Temporarily fit crankshaft pulley bolt and check
that crankshaft rotates freely and smoothly.
10.Tighten each pair of main bearing cap bolts to
133 Nm in the order No. 2, No. 4, No. 1 and
No. 5. Check that crankshaft rotates freely and
smoothly after tightening each pair of bolts.
11.Remove seal guidesLRT-12-035and select
feeler gauges to a thickness of 0.80 mm,
position gauges on number 5 main bearing cap
adjacent to oil seals....

ENGINE
OVERHAUL65
Crankshaft rear oil seal - refit
1.Ensure that oil seal running surface on
crankshaft and oil seal housing mating surface
on cylinder block are clean and oil free and that
bolt holes in cylinder block are clean and dry.
2.Screw 2 slave guide studs into cylinder block.
3.Position new gasket to cylinder block ensuring
that groove along bottom edge of gasket is
towards block.
NOTE: O ring fitted to early engines is no
longer required.4.Slide oil seal protector sleeve over crankshaft,
fit...

ENGINE
66
OVERHAUL Pistons and connecting rods - remove
1.Remove big-end bearings.
2.Suitably identify each piston to its respective
cylinder bore, check that arrow on piston crown
is pointing towards front of cylinder block; if
arrow is not visible, suitably mark piston.
3.Check that plastic tubing is fitted to connecting
rod bolts.
4.Push each piston and connecting rod up
cylinder bore until they can be withdrawn.
5.Remove big-end bearing shells from
connecting rods.
CAUTION: Big-end bearing shells...

ENGINE
OVERHAUL67
Pistons - remove
1.Suitably identify each piston to its connecting
rod, note position of bearing shell tag recess in
connecting rod relative to arrow on piston
crown.
2.Remove and discard circlips retaining gudgeon
pin.
3.Push gudgeon pin out of piston, remove
connecting rod. Retain gudgeon pins and
connecting rods with their respective pistons.Pistons and connecting rods - inspection
1.Remove carbon from piston using fine emery
cloth soaked in oil.
2.Measure and record piston diameter...

ENGINE
68
OVERHAUL
3.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston into
number 1 cylinder bore until bottom of skirt is
30 mm from top of bore.
4.Using feeler gauges, check clearance between
left hand side of piston and cylinder bore =
0.075 mm( viewed from front of cylinder block
).
5.Repeat above procedures for remaining
pistons. If piston to cylinder bore clearance for
any piston exceeds figure given, cylinder block...