Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual
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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 carryoiltothe connecting rodbig-end bearings (8).The camshaft bearings(9)are supplied with oilfrom themain oilgallery. An internal oilwayfromthecamshaft frontbearing connects thecylinder blocktothe cylinder headand feeds oiltothe rocker shaftassembly (10), lubricating thevalves andsprings. The pistons, gudgeon pinsandsmall endbushes are lubricated andcooled byoiljets (11) which are supplied fromthemain oilgallery viarelief valves which allowtheoiltoflow atapre-determined pressure.Oil pressure iscontrolled byapressure reliefvalve (12) incorporated inthe timing casehousing together withtheoilpump. Thevalve allows excess oil tobe recirculated backintotheoilfeed gallery. The rotor typeoilpump isdriven by2flats machined on the front ofthe crankshaft. Oil cooling ismaintained byan oilcooler whichis integral withtheradiator andlinked toadaptors on the oilfilter head bypre-formed feedandreturn hoses. Athermostatic valveinthe filter head allows oil toflow tothe cooler whenitreaches a pre-determined temperature.
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 areburned inthe combustion chamber.
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 cover.
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. Automatic gearbox 12.Rotate crankshaft clockwiseusingcrankshaft pulley boltuntil toolLRT-12-044 canbe inserted throughholeinengine plateandinto slot indrive plate. 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 softmaterial. 18. Slacken butdonot remove boltsecuring timing belt tensioner pulley,movepulley untiltension is removed frombelt. 19. Remove nutand washer securing idlerpulley. 20. Release idlerpulley fromtiming belt,remove pulley. 21. Release timingbeltfrom gears, discard belt.
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: Donot remove 3bolts securing hub plate togear.
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 plate isaligned withtiming pinhole in pump hub. 6. Fit3bolts, position slotsingear mid-way under bolt heads, lightlytighten bolts. CAUTION: Donot fitbolts through elongated slotsinhub plate. Ensure gear does notmove asbolts aretightened. 7. Insert timing pinLRT-12-045 inhub plate and injection pumphub.Iftiming pincannot be inserted, slackenboltsandrotate gearuntilpin can befitted, lightly tighten bolts.
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 usingcrankshaft pulleyboltuntil tool LRT-12-044 canbeinserted inslot indrive plate. 14. Check thatcrankshaft Woodruffkeyisaligned with arrow ontiming beltrear cover. 15. Ifnecessary, rotatecamshaft timinggearusing the centre boltuntil timing markongear is aligned withtiming markontiming beltrear cover. 16. Remove crankshaft pulleybolt.
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. Check thattensioner pulleyboltisfinger tight. 6. Temporarily fitcrankshaft pulleyboltto crankshaft. Adjust tension 1. Ensure toolsLRT-12-044 andLRT-12-045 are stillfitted.2.Position adial type torque wrench andsuitable extension tohole intensioner bracketkeeping the torque wrench positioned vertically. 3. Tension timingbeltto: Used belt-12 Nm New belt-15 Nm 4. Keeping timingbeltatthe correct tension, tighten tensioner boltto45 Nm.