Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

ENGINEOVERHAUL 59
Crankshaft
-regrinding
NOTE: Crankshaft journalsmaybe
reground tothe following dimensions.
Main bearing journals =63.225 to63.237 mm
Big-end bearingjournals =58.475 to58.494 mm
CAUTION: Rotationofcrankshaft mustbe
in an ANTI-CLOCKWISE directionwhen
viewed fromflywheel endofcrankshaft.
1. Grind journals ensuring thatgrinding wheel
travels beyond edgeofjournal Ato avoid
formation ofastep B.
CAUTION: Takecarenottodamage fillet
radius C.
2. Final finishing shouldbecarried outusing a
static...

ENGINE 60OVERHAUL
Main
bearing clearance -checking
CAUTION: Ifcrankshaft hasbeen
reground, oversizemainbearing shells
must befitted.
1. Degrease newmain bearing shellsandensure
all traces ofoil are removed fromcrankshaft
journals.
2. Fitnew main bearing shellstosaddles and
main bearing capsensuring thattags are
located inrecesses insaddles andbearing
caps.
NOTE: Number 5main bearing shellsare
wider thannumbers 1to 4.
3. Using assistance, fitcrankshaft.
4. Place apiece ofPlastigage acrosswidthof
each...

ENGINEOVERHAUL 61
Crankshaft
end-float-checking
1. Lubricate uppermainbearing shellsand
crankshaft mainbearing journals withengine
oil.
2. Lubricate newstandard sizethrust washers
with engine oiland position washers inrecess
in centre mainbearing saddle.
NOTE:Grooved sideofwashers mustface
outwards.
3. Using assistance, fitcrankshaft.
4. Attach aDTI torear face ofcylinder blockwith
stylus contacting endofcrankshaft; push
crankshaft fullyrearwards andzero gauge.
5. Push crankshaft fullyforwards...

ENGINE 62OVERHAUL
Big-end
bearingclearance -checking
1. Fitpistons andconnecting rods.
2. Degrease newbig-end bearingshells.
3. Fitbig-end bearingshellstoconnecting rods
ensuring thattagislocated inrecess in
connecting rod.
4. Fitbig-end bearingshellstobearing caps
ensuring thattagislocated inrecess incap.
5. Temporarily fitcrankshaft pulleyboltand rotate
crankshaft tobring numbers 1and 4journals to
BDC.
6. Remove alltraces ofoil from crankshaft
journals.
7. Pull numbers 1and 4connecting rodsonto...

ENGINEOVERHAUL 63
Crankshaft,
mainandbig-end bearings -refit
Crankshaft andmain bearings
CAUTION: Cylinderboresmustbe
inspected beforecrankshaft isrefitted -
Seecylinder block-inspection
1. Lubricate selectedmainbearing shells,thrust
washers andcrankshaft journalswithengine
oil, ensure boltholes inbearing saddles are
clean anddry;fitbearing shellsinmain bearing
caps andsaddles.
2.Fitseal guides LRT-12-035 tocylinder block
ensuring thatedges ofguides areparallel to
edge ofmain bearing caprecess.
3. Using...

ENGINE
64 OVERHAUL
8.
Tighten centremainbearing capbolts to133
Nm.
9. Temporarily fitcrankshaft pulleyboltand check
that crankshaft rotatesfreelyandsmoothly.
10. Tighten eachpairofmain bearing capbolts to
133 Nminthe order No.2,No. 4,No. 1and
No. 5.Check thatcrankshaft rotatesfreelyand
smoothly aftertightening eachpairofbolts.
11. Remove sealguides LRT-12-035 andselect
feeler gauges toathickness of0.80 mm,
position gaugesonnumber 5main bearing cap
adjacent tooil seals.
12. Position asharp bladeonfeeler...

ENGINEOVERHAUL 65
Crankshaft
rearoilseal -refit
1. Ensure thatoilseal running surfaceon
crankshaft andoilseal housing matingsurface
on cylinder blockareclean andoilfree andthat
bolt holes incylinder blockareclean anddry.
2.Screw 2slave guide studsintocylinder block.
3. Position newgasket tocylinder blockensuring
that groove alongbottom edgeofgasket is
towards block.
NOTE:Oring fitted toearly engines isno
longer required. 4.
Slide oilseal protector sleeveovercrankshaft,
fit oil seal andhousing overguide...

ENGINE 66OVERHAUL
Pistons
andconnecting rods-remove
1. Remove big-endbearings.
2. Suitably identifyeachpiston toits respective
cylinder bore,check thatarrow onpiston crown
is pointing towardsfrontofcylinder block;if
arrow isnot visible, suitably markpiston.
3. Check thatplastic tubingisfitted toconnecting
rod bolts.
4. Push eachpiston andconnecting rodup
cylinder boreuntilthey canbewithdrawn.
5. Remove big-endbearingshellsfrom
connecting rods.
CAUTION: Big-endbearingshellsshould
always berenewed.
6....

ENGINEOVERHAUL 67
Pistons
-remove
1. Suitably identifyeachpiston toits connecting
rod, note position ofbearing shelltagrecess in
connecting rodrelative toarrow onpiston
crown.
2. Remove anddiscard circlipsretaining gudgeon
pin.
3. Push gudgeon pinout ofpiston, remove
connecting rod.Retain gudgeon pinsand
connecting rodswiththeir respective pistons. Pistons
andconnecting rods-inspection
1. Remove carbonfrompiston usingfineemery
cloth soaked inoil.
2. Measure andrecord pistondiameter atright
angles...

ENGINE 68OVERHAUL
3.Starting withnumber 1piston, invertpiston and
with arrow onpiston crownpointing towards
REAR ofcylinder block,insertpiston into
number 1cylinder boreuntilbottom ofskirt is
30 mm from topofbore.
4. Using feelergauges, checkclearance between
left hand sideofpiston andcylinder bore=
0.075 mm(viewed fromfrontofcylinder block
).
5. Repeat aboveprocedures forremaining
pistons. Ifpiston tocylinder boreclearance for
any piston exceeds figuregiven, cylinder block
must berebored.
6. Measure...