Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

							ENGINE
OVERHAUL49
Inspecting components
1.Check clutch face of flywheel for scoring or
signs of overheating ( blueing ), if deep scoring
or signs of overheating exist, flywheel must be
replaced.
2.Check teeth of starter ring gear for chipping
and wear, replace ring gear as necessary.Starter ring gear - replace
1.Drill a 3 mm diameter hole to the depth of the
ring gear at the root of 2 teeth.
CAUTION: Ensure drill does not contact
flywheel.
2.Using a cold chisel, split ring gear.
WARNING: Wear suitable eye protection
and cover flywheel with cloth to protect
against flying fragments.
3.Remove ring gear from flywheel.
4.Heat replacement ring gear uniformly to 250
°C. 
						

							ENGINE
50
OVERHAUL
5.Position ring gear to flywheel with square edge
of teeth towards flywheel flange.
6.Press ring gear on to flywheel, allow to air cool.Flywheel - refit
1.Ensure bolt holes in crankshaft are clean and
dry.
2.Ensure 2 slave 8 mm bolts are screwed fully
into flywheel.
3.Using assistance, position flywheel on
crankshaft.
NOTE: Dowel located.
4.Fit and finger tighten 8 bolts.
5.Restrain crankshaft using toolLRT-12-080
and tighten flywheel bolts by diagonal selection
to 146 Nm.
6.Remove toolLRT-12-080and crankshaft
pulley.
7.Remove slave bolts from flywheel. 
						

							ENGINE
OVERHAUL51
DRIVE PLATE
Remove
1.Temporarily fit crankshaft pulley - if removed.
2.Position toolLRT-12-080to crankshaft pulley,
secure using 4 bolts.
3.Restrain crankshaft using toolLRT-12-080
and remove 8 bolts securing drive plate,
discard locking plate - if fitted.
4.Remove drive plate, recover spacer and shims.
NOTE: Dowel located. 
						

							ENGINE
52
OVERHAUL Inspecting components
1.Check starter ring gear teeth for chipping or
wear, replace ring gear if necessary.
2.Check drive plate for visible signs of damage
or distortion, replace drive plate if necessary.Drive plate - refit
1.Check that bolt holes in crankshaft are clean
and dry.
2.Position spacer, less original shims to
crankshaft.
3.Position a straight edge across spacer.
4.Measure and record distance between gearbox
mating flange of drive plate housing and
straight edge.
5.Repeat procedure on opposite side of spacer.
6.Add the 2 measurements obtained together
and calculate the average.
7.Calculate the difference between the average
figure obtained and 12.4 mm.
8.Select shims from the range available which
equal the final figure obtained.
NOTE: Shims are available rising in
increments of 0.1 mm from 1.0 mm to 2.1
mm in thickness. 
						

							ENGINE
OVERHAUL53
9.Position selected shims, spacer and drive plate
to crankshaft.
NOTE: Dowel located.
10.Fit and finger tighten 8 bolts.
NOTE: Locking plate is no longer required.
11.Restrain crankshaft using toolLRT-12-080
and tighten drive plate bolts to 146 Nm.
12.Remove toolLRT-12-080and crankshaft
pulley.FLYWHEEL/DRIVE PLATE HOUSING
Remove
1.Remove flywheel/drive plate.
NOTE: Flywheel housing illustrated.
2.Remove 2 bolts securing top of housing to
cylinder block.
3.Remove 4 bolts securing housing to engine
mountings.
4.Progressively slacken then remove 6 bolts
securing housing to cylinder block.
5.Remove housing. 
						

							ENGINE
54
OVERHAUL Refit
1.Remove all traces of sealant from mating faces
of housing and cylinder block using solvent
from kit GUG 705548GM.
2.Apply a bead of sealant from kit to cylinder
block.
3.Position housing to cylinder block.
4.Fit and finger tighten bolts.
5.Using sequence shown, tighten bolts to 45 Nm.
NOTE: If engine mounting bolts were not
fitted, omit bolts 8, 10, 11 and 12 from
tightening sequence and re-number
accordingly.
6.Fit flywheel/drive plate. 
						

							ENGINE
OVERHAUL55
CRANKSHAFT, CAMSHAFT, PISTONS AND
CYLINDER BLOCK
1.Remove timing belt rear cover.
2.Remove flywheel/drive plate housing.
3.Remove fuel lift pump.
4.Remove cylinder head.
5.Remove sump, oil pick-up and drain pipes.
6.Remove oil filter head.
7.Remove brake servo vacuum pump.Crankshaft rear oil seal - remove
1.Remove 5 bolts securing rear oil seal housing
to cylinder block.
2.Remove and discard oil seal and housing.
3.
Early engines:Remove and discard O ring.
4.Remove and discard gasket. 
						

							ENGINE
56
OVERHAUL Big-end bearings - remove
1.Suitably identify each oil jet tube to its fitted
location.
2.Remove bolt securing each oil jet tube
assembly to cylinder block.
3.Remove oil jet tube assemblies.
NOTE: Dowel located.
4.Recover sealing washers.
CAUTION: Oil jet tube bolts incorporate a
non-return valve.
5.Temporarily fit crankshaft pulley bolt.
6.Suitably identify fitted position of each big-end
bearing cap to its connecting rod and each
connecting rod to its respective cylinder bore.
7.Rotate crankshaft to bring numbers 1 and 4
connecting rods to BDC.
8.Remove and discard 2 nuts securing each
big-end bearing cap.
9.Remove numbers 1 and 4 big-end bearing
caps, recover bearing shells.
10.Slide suitable pieces of plastic tubing over
each connecting rod bolt.
11.Push numbers 1 and 4 connecting rods up
cylinder bores until they are clear of crankshaft
journals.
12.Repeat above procedures to remove numbers
2 and 3 big-end bearings.
CAUTION: Big-end bearing shells must
always be replaced. 
						

							ENGINE
OVERHAUL57
Crankshaft and main bearings - remove
1.Suitably identify each main bearing cap and its
fitted direction in crankcase.
2.Starting at number 3 main bearing cap and
working outwards, progressively slacken, then
remove bearing cap bolts. Keep bolts with their
respective main bearing caps.
3.Using the fingers only, rock each main bearing
cap until it is released from its retaining dowels.
CAUTION: Do not tap main bearing caps
sideways to release.
4.Remove and discard oil seals from number 5
main bearing cap.
5.Recover lower main bearing shells from
bearing caps.
6.Using assistance, remove crankshaft.7.Recover grooved thrust washers and upper
main bearing shells.
CAUTION: Main bearing shells and thrust
washers must always be replaced.
8.Remove pistons and connecting rods. 
						

							ENGINE
58
OVERHAUL Crankshaft - inspection
NOTE: Crankshafts may be reground 0.25
mm undersize on both main and big-end
journals.
See Crankshaft - regrinding.
1.Clean crankshaft and main bearing caps,
ensure oilways are clear.
2.Check main and big-end journals for signs of
scoring, excessive wear and overheating.
3.Check main and big-end bearing journals for
wear and ovality, make 3 checks at 120
°intervals in centre of journals.
Maximum ovality = 0.040 mm
Main bearing journal diameter = 63.475 to
63.487 mm
Service limit = 63.36 mm
Regrind diameter = 63.225 to 63.237 mm
Big-end bearing journal diameter = 58.725 to
58.744 mm
Service limit = 58.637 mm
Regrind diameter = 58.475 to 58.494 mm
4.If bearing journal diameters are less than
service limit, crankshaft may be reground to
specified regrind diameter and 0.25 mm
oversize bearing shells fitted.
5.Using a micrometer, measure diameter at each
end of main and big-end bearing journals.
6.From measurements obtained, calculate taper
of each journal.
Maximum journal taper - end to end = 0.025
mm
7.Support each end of crankshaft in Vee blocks.
8.Position a DTI with stylus contacting centre
main bearing journal.
9.Rotate crankshaft and check run-out does not
exceed 0.076 mm.
CAUTION: If run-out exceeds above figure,
renew crankshaft.