Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

ENGINEOVERHAUL 39
5.Remove 3bolts securing mounting bracketand
baffle platetocylinder block.
6. Remove 2bolts securing mounting bracketto
injection pump,remove bracket.
7.Remove banjoboltsecuring fuelspill return
pipe toinjection pump,discard sealing
washers.
CAUTION: Plugopen connections to
prevent ingressofdirt.
8. Remove 3nuts securing injectionpumpto
timing beltrear cover, remove injection pump.    

ENGINE 40OVERHAUL
Refit
1. Position injection pumptotiming beltrear
cover, fitnuts andtighten to25 Nm.
2. Fitfuel spill return pipe,fitbanjo boltand 2new
sealing washers.
3. Tighten banjoboltto25 Nm.
4. Position mounting brackettoinjection pump
and cylinder block,fitand finger tighten bolts.
5. Tighten mounting bracketboltsto25 Nm inthe
following order:
Mounting brackettocylinder block
Mounting brackettoinjection pump
6. Fitfuel pipes.
7.Position injection pumpgearandhubplate to
injection pumphubensuring...

ENGINEOVERHAUL 41
2.Remove 2bolts securing fuelliftpump to
cylinder block,remove pump,gasket, spacer
and 2ndgasket.
3. Discard gaskets. Refit
1. Remove alltraces ofgasket usingsuitable
gasket removal sprayandaplastic scraper.
2. Position newgaskets andspacer tofuel lift
pump.
3. Fitfuel liftpump ensuring thatoperating lever
is correctly positioned oncamshaft.
4. Fitbolts andtighten to25 Nm.
5. Position fueldelivery pipetofuel liftpump, fit
banjo boltand 2new sealing washers.
CAUTION: Donot fully tighten...

ENGINE 42OVERHAUL
FUEL
INJECTORS
Remove
1. Disconnect eachpairoffuel pipes fromfuel
injection pumpandinjectors.
2.Remove banjoboltsecuring fuelspill return
pipes toinjector, removeanddiscard 2sealing
washers.
CAUTION: Plugbroken connections to
prevent ingressofdirt.
3. Remove nutsecuring injectorclamp,remove
clamp.
4. Remove injector,removeanddiscard sealing
washer.
WARNING: Donot attempt toremove
injectors usingengine compression,
either useanopen ended spanner on
injector bodyandrotate injector...

ENGINEOVERHAUL 43
Refit
1. Clean alltraces ofcarbon frominjector ports.
2. Fitanew sealing washer toinjector, insert
injector intoport ensuring thatspill return banjo
bolt hole faces awayfromcylinder head.
3. Position injectorclamptoinjector andcylinder
head studensuring thatraised piponconcave
face ofclamp facesupwards.
4. Fitand tighten injector clampnutto25 Nm.
5. Position spillreturn pipestoinjector, fitbanjo
bolt and 2new sealing washers.
6. Tighten banjoboltto10 Nm.
7. Repeat aboveprocedures...

ENGINE 44OVERHAUL
BRAKE
SERVOVACUUM PUMP
Remove 1. Ensure thatnumber 1piston isat TDC.
CAUTION: Rotatecrankshaft ina
clockwise direction.
2.Noting theirfitted positions, progressively
slacken 5bolts untilallloading isremoved from
vacuum pumppiston.
NOTE: Thesixth boltwas removed during
air cleaner bracket removal.
3. Remove bolts.
4. Remove vacuumpump,remove anddiscard
gasket. Refit
1. Remove alltraces ofgasket usingsuitable
gasket removal sprayandaplastic scraper.
2. Ensure number 1piston isstill...

ENGINEOVERHAUL 45
SUMP,
OILPICK-UP ANDDRAIN PIPES
Sump -remove
1. Using sequence shown,progressively slacken,
then remove 22bolts securing sumptocylinder
block.
2. Remove sump Oil
pick-up anddrain pipes -remove1. Remove boltsecuring oilpick-up pipeflange to
timing beltrear cover.
2. Remove 4bolts securing oilpick-up anddrain
pipes tocylinder blockandmain bearing cap
bolts.
3. Remove oilpick-up anddrain pipes.
4. Remove anddiscard Oring and gasket.    

ENGINE 46OVERHAUL
Oil
pick-up anddrain pipes -refit
1. Clean oilpick-up anddrain pipes andstrainer,
remove alltraces ofgasket usingsuitable
gasket removal sprayandaplastic scraper.
2. Ensure boltholes intiming beltrear cover,
cylinder blockandmain bearing capbolts are
clean anddryand thatalltraces ofLoctite are
removed fromholes inmain bearing capbolts.
CAUTION: Donot use atap toremove
Loctite fromboltholes.
3.Lubricate anew Oring with engine oiland fit
to oil pick-up pipe.
4. Position anew gasket...

ENGINEOVERHAUL 47
Sump
-refit
1. Clean sumpandremove alltraces ofsealant
using solvent fromkitGUG 705548GM.
2. Apply a2m m bead ofHylomar InstantGasket
302 (black) tosump flange ensuring that
sealant isapplied inboard ofbolt holes.
3. Position sumptocylinder block.
CAUTION: Sumpmustbefitted within 30
minutes ofapplying sealant.
4.Fit22 sump boltsandtighten insequence
shown to25 Nm.
5. Check thatsump drainplugistightened to35
Nm. FLYWHEEL
ANDSTARTER RINGGEAR
Flywheel -remove
1. Screw 2slave 8m m bolts...

ENGINE 48OVERHAUL
2.Temporarily fitcrankshaft pulley.
3. Position toolLRT-12-080 tocrankshaft pulley,
secure with4bolts.
4. Restrain crankshaft pulleyusingtool
LRT-12-080 andremove 8bolts securing
flywheel; discardlockingplate-if fitted.
5. Using assistance, removeflywheel using2
slave bolts.
NOTE: Dowellocated.