Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual
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300TDi ENGINE OVERHAUL MANUAL This engine isfitted tothe following Modelsfrom 1995 onwards: Discovery DefenderRange RoverClassic Publication PartNo.LRL 0070ENG Published byRover Technical Communication Ó 1997 Rover Group Limited
INTRODUCTIONINTRODUCTION 1 INTRODUCTION How touse this manual To assist inthe use ofthis manual thesection titleis given atthe topand therelevant sub-section isgiven at the bottom eachpage. This manual contains procedures foroverhaul ofthe engine. Forallother information regarding adjustments, removalofoil seals andengine, consult theRepair Manual forthe model concerned. This manual isdivided into3sections: Description andOperation,Overhaul andData,Torque &Tools. To assist filingofrevised information, each sub-section isnumbered frompage 1. Individual itemsaretobe overhauled inthe sequence inwhich theyappear inthis Manual. Items numbered inthe illustrations arereferred tointhe text.Overhaul operations includereference toService Tool numbers andtheassociated illustrationdepicts the tool. Where usageisnot obvious thetool is shown inuse. Operations alsoinclude reference to wear limits, relevant data,torque figures, specialist information anduseful assembly details. WARNINGS, CAUTIONSandNotes havethe following meanings: WARNING: Procedures whichmustbe followed precisely toavoid thepossibility of injury. CAUTION: Callsattention toprocedures which mustbefollowed toavoid damage to components. NOTE: Giveshelpful information. References With theengine andgearbox assembly removed, the crankshaft pulleyendofthe engine isreferred to as the front. Operations coveredinthis manual donot include reference totesting thevehicle afterrepair. Itis essential thatwork isinspected andtested after completion andifnecessary aroad testofthe vehicle iscarried outparticularly wheresafety related itemsareconcerned DimensionsThe dimensions quotedaretodesign engineering specification withService limitswhere applicable.
INTRODUCTION 2INTRODUCTION REPAIRS ANDREPLACEMENTS When replacement partsarerequired itis essential that only Land Rover recommended partsareused. Attention isparticularly drawntothe following points concerning repairsandthefitting ofreplacement parts andaccessories. Safety features andcorrosion prevention treatments embodied inthe carmay beimpaired ifother than Land Rover recommended partsarefitted. Incertain territories, legislation prohibitsthefitting ofparts not to the manufacturers specification. Torque wrench settingfigures giveninthis Manual must beused. Locking devices, wherespecified, must befitted. Ifthe efficiency ofalocking deviceis impaired duringremoval itmust berenewed. The terms ofthe vehicle Warranty maybe invalidated bythe fitting ofother thanLand Rover recommended parts.AllLand Rover recommended parts havethefullbacking ofthe vehicle Warranty. Land Rover Dealers areobliged tosupply onlyLand Rover recommended parts. SPECIFICATION Land Rover areconstantly seekingtoimprove the specification, designandproduction oftheir vehicles and alterations takeplace accordingly. Whileevery effort hasbeen made toensure theaccuracy ofthis Manual, itshould notberegarded asan infallible guide tocurrent specifications ofany particular component orvehicle. This Manual doesnotconstitute anoffer forsale of any particular component orvehicle. LandRover Dealers arenotagents ofthe Company andhave no authority tobind themanufacturer byany expressed or implied undertaking orrepresentation.
ENGINE DESCRIPTION ANDOPERATION 1 This page isintentionally leftblank
ENGINE DESCRIPTION ANDOPERATION 3 CYLINDER BLOCK,PISTONS ANDCAMSHAFT 1. Top compression ring 2. 2nd compression ring 3. Oil control ring 4. Piston 5. Gudgeon pincirclips 6. Gudgeon pin 7. Connecting rod 8. Brake servovacuum pumpgasket 9. Core plug 10. Connecting rodbolt 11. Big-end bearingshell 12. Push rod 13. Cam follower slide 14. Roller 15. Cam follower guide 16. Guide retaining bolt 17. Dipstick 18. Dipstick tube 19. Dipstick tubebolt 20. Camshaft 21. Oiljettube 22. Drive pin 23. Camshaft thrustplate 24. Camshaft bearings 25. Main bearing shell 26. Baffle plate 27. Core plugs 28. Oilpressure switch 29. Thermostatic valveassembly 30. Oilfilter head 31. Fuel liftpump 32. Fuel liftpump gaskets 33. Spacer -if fitted 34. Brake servovacuum pump 35. Crankcase breatherpipe 36. Oilfilter head gasket 37. Baffle plategasket 38. Oilfilter element
ENGINE DESCRIPTION ANDOPERATION 5 CRANKSHAFT, SUMPANDOILPUMP 1. Crankshaft 2. Woodruff key 3. Main bearing shell 4. Main bearing cap-front 5. Main bearing capbolt 6. O ring -oil pick-up pipe 7. Oil pick-up pipeandstrainer 8. Sump bolt 9. Oil drain pipe 10. Sump 11. Gasket -oil drain pipe 12. Main bearing cap-rear 13. Rear mainbearing capoilseal 14. Crankshaft thrustwashers 15. Main bearing cap-centre 16. Big-end bearingcap 17. Big-end bearingcapnut 18. Big-end bearingshell 19. Oiljettube banjo bolt 20. Oiljettube 21. Oilpump 22. Timing beltrear cover 23. Plug 24. Oilpressure reliefvalve spring 25. Oilpressure reliefvalve plunger