Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

ENGINEOVERHAUL 69
11.Assemble eachbig-end bearingcapless
bearing shellstoits respective connecting rod.
12. Fitand tighten big-end bearingcapnuts to59
Nm.
13. Slacken thenutonone side ofconnecting rod.
14. Using feelergauges, checkthatthere isno gap
between bearingcapand connecting rodon
the side ofthe cap with theslackened nut.
CAUTION: Ifclearance exists,connecting
rod must bereplaced.
15. Remove nutsandbig-end bearingcaps.
CAUTION: Retainnutsandbearing caps
with their respective connecting rod
16....

ENGINE 70OVERHAUL
Piston
rings-checking
CAUTION: Priortochecking pistonring
gaps incylinder bores,boresmustbe
inspected, measuredandifreboring has
been carried out,theappropriate oversize
pistons andrings used.
1.Check fittedgapofeach newpiston ringinturn
with ringpositioned half-waydowncylinder
bore. Fitted gapofrings inbores:
Top compression =0.40 to0.65 mm
2nd compression =0.30 to0.50 mm
Oil control rails=0.30 to0.60 mm
CAUTION: Ensurethatpiston ringsare
suitably identified withthecylinder borein...

ENGINEOVERHAUL 71
6.Check ringtogroove clearances:
Top compression =0.167 to0.232 mm
2nd compression =0.05 to0.08 mm
Oil control rails=0.05 to0.08 mm
7. Ifnew ringtogroove clearances areexcessive,
new pistons mustbefitted. Oil
jettubes -inspection
1. Check thatoilpassage ineach oiljet tube is
clear.
2. Thoroughly cleanbanjo bolts.
3. Insert apiece ofstiff wire inend ofbanjo bolt
and check thatnon-return valvecanbe
depressed toopen position andreturns to
closed position underspring pressure.
CAUTION:...

ENGINE 72OVERHAUL
Pistons
andconnecting rods-refit
1. Position pistonringgaps at60 °to each other
and away fromthrust sideofpiston (lefthand
side ofpiston whenviewed fromfront).
2. Slide suitable lengthsoftubing overconnecting
rod bolts.
3. Ensure cylinder boresareclean.
4. Lubricate pistons,ringsandcylinder boreswith
engine oil.
5.Compress pistonringsusing asuitable clamp.
6. Insert piston andconnecting rodinto cylinder
bore ensuring thatpiston isin its correct fitted
order andarrow onpiston...

ENGINEOVERHAUL 73
Camshaft
-remove
1. Remove oiljet tube.
2. Clean areaaround baffleplate.
3. Note fitted position of3bolts securing baffle
plate.
4. Remove 3bolts securing baffleplateto
cylinder block,remove plate.
5. Remove anddiscard gasket.
CAUTION: Donot remove camfollower
guide retaining boltsuntilslides and
rollers havebeen removed, keep
components ofeach camfollower assembly in
their fitted order.
6. Using longnosed pliers,remove camfollower
slide.
7. Remove rollerandsuitably identifywhichside
of...

ENGINE 74OVERHAUL
11.Remove 2bolts securing camshaft thrustplate
to cylinder block,remove anddiscard plate.
12. Carefully withdrawcamshaft takingcarenotto
drop endofcamshaft ontobearings. Camshaft,
bearingsandcam followers -
inspection
1. Check camshaft camsandbearing journals for
overheating, wearandscoring, replace
camshaft ifnecessary.
2. Ifcamshaft isreplaced, newbearings mustbe
fitted.
3. Check timinggeardrive pinforsecurity.
4. Check camshaft bearingsforoverheating, wear
and scoring...

ENGINEOVERHAUL 75
Camshaft
-refit andcheck end-float
1. Remove alltraces ofgasket frombaffle plate
and cylinder blockusing suitable gasket
removal sprayandaplastic scraper.
2. Lubricate cams,journals andbearings with
engine oil.
3. Ensure thrustplateboltholes incylinder block
are clean anddry.
4.Carefully insertcamshaft intocylinder block
taking carenottodrop endofcamshaft onto
bearings.
5. Fitanew thrust plate,fitbolts andtighten to9
Nm.
6. Temporarily fitcamshaft timinggear,fitand
tighten...

ENGINE 76OVERHAUL
15.Insert eachcamfollower guideintoitsoriginal
location inthe cylinder block.
16. Fitnew retaining bolt,locate endofbolt incam
follower guide.
17. Tighten boltto14 Nm.
18. Fitroller ensuring thatreference markmade
during removal istowards frontofcylinder
block.
19. Fitcam follower slideensuring thatword
FRONT ormark Fistowards frontofcylinder
block.
20. Repeat aboveprocedures forremaining cam
follower assemblies.
21. Fitadry, new gasket tobaffle plate.
22. Fitbaffle plate,fit3bolts...

ENGINEOVERHAUL 77
9.
Check cylinder boreoverall wear,measure at
several pointsfromsidetoside, thelargest
diameter recorded isthe maximum wear.
Cylinder bore-standard =90.47 mm
1st rebore oversize =90.73 mm
2nd rebore oversize =90.98 mm
Maximum wear=0.177 mm
CAUTION: Donot de-glaze cylinderbores.
10. Cylinder boreswhich areworn inexcess of
0.177 mmover theabove boresizes mustbe
rebored andtheappropriate oversizepistons
and rings fitted.
CAUTION: Cylinderboresmustbehoned
to finished size.
11. Fitoilpick-up...

ENGINE
DATA, TORQUE &TOOLS 1
ENGINE
DATA
Rocker shaft
Rocker shaftwear-maximum 0.025mm
..................
Rocker armshaft tobush clearance -maximum 0.12mm
....
Valve clearance -inlet andexhaust 0.20mm
..............
Oil pump
Outer rotortohousing clearance 0.025to0.075 mm
................
Inner toouter rotorclearance 0.025to0.075 mm
..................
Outer rotorend-float 0.026to0.135 mm
.........................
Relief valvespring freelength 68.0mm
..................
Cylinder head
Cylinder headmaximum...