Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

							ENGINEOVERHAUL 9
5.Check thattiming pinLRT-12-045 moves
freely inand outofinjection pumphub,ifpin
does notmove freely, slacken 3bolts, move
gear slightly andre-check.
6. When timing pinmoves freely,tighten 3bolts
to 25 Nm.
7. Remove timingpinLRT-12-045 and
flywheel/drive platelocking toolLRT-12-044.
8. Rotate crankshaft twiceinaclockwise direction
using crankshaft pulleyboltuntil flywheel/drive
plate locking toolLRT-12-044 canberefitted.
9. Slacken timingbelttensioner securingboltand
re-tension timingbelt.
10. Tighten tensioner boltto45 Nm.
11. Fittiming pinLRT-12-045 intofuelinjection
pump gearhubplate andpump hub.Iftiming
pin cannot beinserted, slackeninjection pump
gear bolts, rotate pumpshaftusing shaftnut
until pinslides easilyintopump hub,Tighten
bolts to25 Nm.
12. Tighten camshaft gearboltto80 Nm.
13. Remove timingpinand flywheel/drive plate
locking tools.
14. Fitplug toflywheel housing, tightento12 Nm.
15. Remove crankshaft pulleybolt.
16.Support timingbeltfront cover onsuitable
blocks ofwood.
17. Smear anew crankshaft oilseal withengine
oil.
18. Using toolLRT-12-077, fitoil seal from inside
face offront cover.
19.Fitadry, new gasket totiming beltrear cover.
20. Position timingbeltfront cover torear cover.
21. Fitbolts ofthe correct lengthinpositions
shown.     
						

							ENGINE 10OVERHAUL
22.Tighten boltsinsequence shownto25 Nm.
23. Lightly oilcrankshaft spigot,fitWoodruff key
and crankshaft pulley.
24.Position toolLRT-12-080 tocrankshaft pulley,
retain toolusing 4bolts.
25. Fitcrankshaft pulleyflange headbolt.
26. Restrain crankshaft andtighten boltto80
Nm,then further90.°
27. Remove toolLRT-12-080.   
						

							ENGINEOVERHAUL 11
ROCKER
SHAFT
Remove
1. Disconnect breatherhosesfromcrankcase
breather cycloneunit.
2. Remove boltsecuring cycloneunittorocker
cover.
3. Remove cycloneunit,remove anddiscard O
ring.
4. Disconnect breatherhosesfromcylinder block
and rocker cover.
5.Remove 3flange nutssecuring rockercover,
recover sealingwashers.
6. Remove rockercover,remove anddiscard
gasket.
7. Slacken locknutoneach tappet adjusting
screw, slacken adjusting screwsuntilthey are
clear ofpush rods.
8. Working fromthecentre outwards,
progressively slackenthenremove 3nuts and
2 bolts securing rockershaftpedestals to
cylinder head.
CAUTION: Insertaslave boltinto
pedestals 1and 5to prevent components
sliding offshaft.
9. Remove rockershaftassembly.     
						

							ENGINE 12OVERHAUL
10.Withdraw pushrods.
11. Remove valvecaps.
CAUTION: Keeppushrodsandvalve caps
in their fitted order. Rocker
shaft-dismantling
1. Suitably identifyeachcomponent toits fitted
position.
2. Remove locknutandtappet adjusting screw
from each rocker.
3. Remove slaveboltand pedestal fromendof
rocker shaft.
4. Remove washer,rockerarmandspacer
followed bysecond rockerarm,spacer and
pedestal.
5. Repeat aboveprocedures untilallcomponents
are removed.   
						

							ENGINEOVERHAUL 13
Inspecting
components
1. Measure andrecord diameter ofrocker shaftat
one ofthe pedestal locations.
2. Measure andrecord diameter ofrocker shaftat
each ofthe rocker armlocations.
3. Compare measurements obtainedand
calculate difference betweendiameters. Ifwear
at any rocker shaftlocation exceeds 0.025mm,
a new rocker shaftmustbefitted.
4. Check rockerarmpads forsigns ofwear,
replace rockerarmsasnecessary.
5. Check threads andballends ofeach tappet
adjusting screwforwear. Payparticular
attention toball ends, replace anyshowing
signs offlattening onthe ball ordamage to
threads.
6. Check thateach nutruns freely onadjusting
screw threads.
7. Check eachpushrodforsigns ofwear andfor
straightness, replaceasnecessary.
8. Check valvecapsforsigns ofwear, replace as
necessary.
9. Check rockerarmbushes forscoring and
wear.
10. Assemble eachrocker armtoits fitted location
on rocker shaftandcheck clearance ofbush to
shaft does notexceed 0.12mm.
11. Ifclearance exceedsfiguregiven, bushes must
be replaced. Rocker
armbushes -replace
1. Support rockerarmonbed ofhand press.
2. Using asuitable pilotedmandrel, pressbush
out ofrocker arm.
3. Lubricate replacement bushwithengine oiland
press intorocker armensuring thatlubrication
holes inbush andarm arealigned.
4.Check thatlubrication holesineach rocker arm
are clear.
5. Check thatlubrication holesinrocker shaftare
clear.
6. Check spacers andwashers forwear, replace
as necessary.    
						

							ENGINE 14OVERHAUL
Rocker
shaft-assembling
1. Lubricate allcomponents withengine oil.
2. Assemble rockerarms,spacers, washersand
pedestals torocker shaftensuring thatthey are
in their original fittedpositions.
3. Retain pedestals 1and 5with slave bolts. Rocker
shaft-refit
1. Lubricate pushrodswithengine oiland fitto
their original positions. Ensurethatballend of
each pushrodiscorrectly locatedineach cam
follower slide.
2. Screw eachtappet adjusting screwintoits
respective rockerarmuntil ballend isflush with
underside ofarm; fitbut donot tighten
locknuts.
3. Lubricate valvepadswithengine oiland fitto
their original positions.
4. Position rockershafttocylinder head,fitbut do
not tighten 3nuts.
5. Remove slaveboltsfrompedestals 1and 5,fit
but donot tighten 2bolts.
6. Locate eachpushrodinturn beneath its
respective tappetadjusting screwandtighten
each screw untilballend locates inrecess in
push rod.
7. Working fromthecentre outwards,
progressively tighten3nuts and2bolts to5
Nm. 
						

							ENGINEOVERHAUL 15
8.Make asuitable pointerfromwelding rodand
position itto number 1pedestal stud.
9. Temporarily fitanut tosecure pointer tostud.
10. Assemble degreeplateLRT-12-007 toa
suitable torquewrench orextension bar.
11. Tighten thecentre pedestal nutafurther 50°.
12. Tighten 2pedestal boltsandnumber 5
pedestal nutafurther 50°.
13. Remove pointerandsecure itto number 5
pedestal stud.
14. Tighten number 1pedestal nutafurther 50°.
15. Remove pointer.
16. Adjust valveclearances.
17. Thoroughly cleanmating facesofrocker cover
and cylinder head,remove alltraces ofgasket
material usinggasket removal sprayanda
plastic scraper.   
						

							ENGINE 16OVERHAUL
18.Check sealing washers fordamage or
distortion, replaceasnecessary.
19. Position anew gasket -dry torocker cover.
20. Position rockercovertocylinder head,fit3
flange nutsandworking fromcentre outwards,
tighten to10 Nm.
21. Lubricate anew Oring with engine oiland fit
to crankcase breathercycloneunit.
22. Fitcyclone unittorocker cover,fitbolt and
tighten to9Nm.
23. Connect breatherhosestocyclone unit,rocker
cover andcylinder block.   
						

							ENGINEOVERHAUL 17
VALVE
CLEARANCES -ADJUST
CAUTION: Toprevent possibility of
damage tocam follower seatings, itis
essential thatballends oftappet adjusting
screws areseated inrecess inpush rodsand
that ballend ofeach push rodiscorrectly
located incam follower slide.
1. Rotate crankshaft bymeans ofcrankshaft
pulley boltinaclockwise directionuntilnumber
8 valve (counting fromfrontofengine )is fully
open.
2. Using feelergauges andascrewdriver, adjust
clearance ofnumber 1valve.
Valve clearance -all valves =0.20 mm
3. Tighten tappetadjusting screwlocknut when
clearance iscorrect.
4. Adjust theremaining valveclearances inthe
following sequence:
Adjust number 3clearance withnumber 6
valve fullyopen
Adjust number 5clearance withnumber 4
valve fullyopen
Adjust number 2clearance withnumber 7
valve fullyopen
Adjust number 8clearance withnumber 1
valve fullyopen
Adjust number 6clearance withnumber 3
valve fullyopen
Adjust number 4clearance withnumber 5
valve fullyopen
Adjust number 7clearance withnumber 2
valve fullyopen
5. Upon completion, re-checkallclearances and
adjust asnecessary.   
						

							ENGINE 18OVERHAUL
CYLINDER
HEAD
Remove 1. Remove rockershaft.
2. Remove fuelinjectors.
3. Remove glowplugs.
4.Using sequence shown,progressively slacken
then remove anddiscard 18bolts securing
cylinder head.
5. Using assistance, removecylinder head.
NOTE:Dowellocated.
6. Remove cylinderheadgasket.
CAUTION: Identifycylinder headgasket
thickness bythe number ofholes inthe
edge ofthe gasket between numbers 3
and 4injector ports.Replacement gasketmust
be ofthe same thickness asthe original unlessa
replacement cylinderhead,crankshaft and/or
pistons arefitted.
-See Cylinder headgasket
selection.
7. Discard cylinder headgasket.
8.Remove 2bolts securing coolantoutletelbow.
9. Remove coolantoutletelbow.
10. Remove thermostat fromhousing.
11.Remove 4bolts securing thermostat housingto
cylinder head,remove housing.
12. Remove anddiscard gasket.
13. Remove alltraces ofgasket usingsuitable
gasket removal sprayandaplastic scraper.