Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

ENGINE
DESCRIPTION ANDOPERATION 17
Lubrication The
engine lubrication systemisof the wet sump
type, oilpressure beingprovided bythe rotor typeoil
pump (1)driven directly bythe crankshaft.
Oil isdrawn fromthesump (2)through thestrainer
(3), suction pipe(4)and passes through internal
drillings inthe cylinder blocktoan external, fullflow
filter (5).Further drillings feedoiltothe cylinder
block mainoilgallery (6)which, inturn, supplies the
crankshaft mainbearings (7).Cross drillings inthe
crankshaft...

ENGINE 18DESCRIPTION ANDOPERATION
Crankcase ventilationsystem
A breather cycloneunit(1),fitted tothe right hand
side ofthe rocker covercontrols therate atwhich air
is purged fromthesump, viaahose (2)from the
camshaft sidecover tothe rocker coverandextracts oil
from thegaseous atmosphere. Theoilthen drains
back tothe sump through ahose andflanged pipe
connection (3).The residues aredrained-off from
the topofthe cyclone breather andpass through a
hose (4)into theengine viathe turbocharger where
they...

ENGINEOVERHAUL 1
TIMING
BELT,TENSIONER ANDGEARS
Timing belt-remove
1. Position toolLRT-12-080 tocrankshaft pulley,
retain with4bolts.
2. Restrain crankshaft usingtoolLRT-12-080
and remove crankshaft pulleyflange headbolt.
NOTE: Boltandwasher fittedtoearly
engines.
3. Remove toolLRT-12-080 .
4.Position toolLRT-12-049 andthrust button,
part oftool LRT-12-031 tocrankshaft pulley,
remove pulley,recover Woodruff key.
5.Using sequence shown,progressively slacken
then remove 14bolts securing timingbeltfront...

ENGINE 2OVERHAUL
6.Remove timingbeltfront cover.
7. Remove anddiscard gasket.
8. Remove anddiscard crankshaft frontoilseal
from timing beltfront cover.
9. Temporarily fitcrankshaft pulleyboltto
crankshaft.
Manual gearbox
10.Remove plugfrom bottom offlywheel housing.
11. Rotate crankshaft clockwiseusingcrankshaft
pulley boltuntil toolLRT-12-044 canbe
located inslot inflywheel.
CAUTION: Donot rotate crankshaft
anti-clockwise anddonot use camshaft or
fuel injection pumpgearbolts torotate
crankshaft....

ENGINEOVERHAUL 3
Allengines
13. Check thattiming markoncamshaft pulleyis
aligned withmark ontiming beltrear cover and
the crankshaft Woodruffkeyisaligned withthe
arrow castonthe rear cover.
14. Remove crankshaft pulleybolt.
15. Insert timing pinLRT-12-045 intofuelinjection
pump gearhubplate andinjection pumphub.
16.Slacken butdonot remove centreboltsecuring
camshaft drivegeartocamshaft.
17. Iftiming beltisto be refitted, markdirection of
rotation onoutside surface ofbelt with chalk or
similar...

ENGINE 4OVERHAUL
Timing
belttensioner andtiming gears-remove
1. Remove crankshaft gearusing tools
LRT-12-031 andLRT-12-078, recover
Woodruff keyfrom crankshaft.
2. Remove anddiscard Oring.
3.Remove boltand slotted washer securing
timing belttensioner pulley,remove pulley
together withtensioner bracket.
4. Recover flangedspacerfromidlerpulley stud.
5.Remove centreboltand washer securing
camshaft timinggear,remove gearandhub
plate asan assembly.
NOTE: Laterengines arefitted witha
flange headbolt.
CAUTION:...

ENGINEOVERHAUL 5
6.Remove 3bolts securing fuelinjection pump
gear andhubplate topump hub.
CAUTION: Donot remove nutsecuring
hub tofuel injection pump.
7. Remove timingpinLRT-12-045.
8. Remove fuelinjection pumpgearandhub
plate. Inspecting
components
1. Check timinggearteeth forburrs.
2. Remove alltraces ofgasket fromtiming belt
front andrear covers usingsuitable gasket
removal sprayandaplastic scraper.   

ENGINE 6OVERHAUL
Timing
belttensioner andgears -refit
1. Smear anew Oring with engine oiland fitto
crankshaft.
2. FitWoodruff keyinslot incrankshaft.
3. Fitcrankshaft gearontocrankshaft andusing
a soft mallet, tapgear fullyhome.
4.Position camshaft timinggearandhubplate to
camshaft, fitbolt and washer, fingertighten
bolt. Donot tighten boltatthis stage.
NOTE: Laterengines arefitted witha
flange headbolt.
5.Position fuelinjection pumpgearandhubplate
to fuel injection pumphubensuring thatcut-out
in hub...

ENGINEOVERHAUL 7
8.Position flangedspaceronidler pulley stud.
9. Fittiming belttensioner pulleyandbracket
ensuring thathole intensioner bracketis
located onflanged spacer.
10. Fitslotted washer withtheslot vertical andfit
bolt, finger tight.
11. Temporarily fitcrankshaft pulleyboltto
crankshaft.
NOTE: Flywheel illustrated
12.
Manual gearbox:Rotatecrankshaft clockwise
using crankshaft pulleyboltuntil tool
LRT-12-044 canbeinserted inslot inflywheel.
13.
Automatic gearbox:Rotatecrankshaft
clockwise...

ENGINE 8OVERHAUL
Timing
belt-refit andadjust tension
Refit
1. Using thefingers only,fitanew timing beltto
timing gearskeeping slackportion ofbelt on
idler pulley sideofbelt. Ifnecessary, rotatefuel
injection pumpgearanti-clockwise toalign
gear teeth withthose oftiming belt.
CAUTION: Iforiginal timingbeltisto be
refitted, ensuredirection ofrotation mark
is facing correct way.
2. Fitidler pulley.
3. Fitidler pulley nutand tighten to45 Nm.
4. Ensure thattiming beltiscorrectly locatedon
timing gears.
5....