Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

							ENGINEOVERHAUL 19
14.Remove 2bolts securing enginefrontlifting
bracket, removebracket. Valves
andsprings -remove
1. Support cylinderheadclearofvalves, usea
hollow driftand tapeach valve spring capto
free collets.
2. Position cylinderheadonitsside.
3. Using toolLRT-12-034 compressvalvespring.
4. Remove 2collets fromvalve stem.
5. Remove toolLRT-12-034.    
						

							ENGINE 20OVERHAUL
6.Remove springcup,valve spring andspring
seat. Keep components intheir fitted order.
7. Remove anddiscard valvestemoilseal.
8. Remove valve,andretain infitted order.
9. Repeat aboveprocedures forremaining
valves. Cylinder
head-inspection
1. Decarbonise cylinderhead.
2. Examine cylinderheadforcracks, pay
particular attentiontoarea between inletand
exhaust valveseats. Cracks indicate engine
has overheated andcylinder headmustbe
replaced.
3. Check coreplugs forsigns ofcorrosion and
leakage, replaceasnecessary.4. Check cylinder headforwarping usinga
straight edgeandfeeler gauges.
Maximum warping=0.08 mm
CAUTION: Cylinderheadmust notbe
refaced, ifwarping exceeds figuregiven,
head must bereplaced.
5. Check valveseatinserts forburning, pittingor
damage, replaceinsertsifpitting cannot be
removed byvalve lapping-in orrefacing.   
						

							ENGINEOVERHAUL 21
Valve
springs -inspection
1. Check freelength ofeach spring =46.28 mm
2. Check thatend coils ofeach spring aresquare
to body ofspring. Valves
andguides -inspection
1. Remove carbonfromvalves.
2. Examine headofeach valve forcracks and
burning andvalve seatforpitting orburning,
replace valvesasnecessary.
3. Check valveseating facesforpitting, iflight
pitting cannot beremoved duringvalve
grinding operations, valvesmayberefaced.
CAUTION: Ifrefacing resultsinvalve head
stand downbeing exceeded, valvesmust
be replaced.
4.Check valveseating faceangles.
Inlet =60 °00 to60 °30 -included angle=120
° Exhaust =45 °00 to45 °30 -included angle=
90 °
5. Reface orreplace valvesasnecessary.
6. Check eachvalve stemforwear, measure at
each endandcentre ofvalve stem.
Inlet =7.96 mm
Exhaust =7.94 mm
7. Replace anyvalve withstems thatareworn.   
						

							ENGINE 22OVERHAUL
8.Insert anew valve intoeach guide inturn and
with head ofvalve positioned 8.0mm above
seat insert, measure sidetoside movement of
valve headusing asuitable DTI.
Maximum valveheadmovement =0.15 mm
9. Replace anyvalve guide which permits valve
head movement inexcess ofthe above figure. Valve
guides -renew
1. Support cylinderhead,combustion face
upwards onblocks ofwood.
2. Using toolLRT-12-036, driftvalve guide outof
cylinder head,discard guide.
3. Clean valveguide bore.
4. Heat cylinder headuniformily to120 °C.
WARNING: Takecarewhen handling
heated cylinder head.   
						

							ENGINEOVERHAUL 23
5.Position cylinderheadonbed ofhand press.
6. Position replacement valveguide tocylinder
head, ensuring thatgroove forvalve stemseal
is facing awayfromcylinder head.
7. Position distance piece,toolLRT-12-515 and
valve guide replacer LRT-12-046 tovalve
guide.
8. Press valveguide intocylinder headuntil
distance piececontacts faceofhead; remove
tools.
9. Allow cylinder headtoair cool. Valve
seatinserts -refacing
CAUTION: Priortorefacing valveseats,
check valveheadstand down. If,after
refacing, valveheadstand downwillbe
below limits, seatinserts mustbereplaced.
1.Support cylinderheadonitsside onsuitable
blocks ofwood.
2. Loosely assemble pilot,toolLRT-12-502 and
a suitable expandable collet,ensuring that
chamfered endofexpander istowards the
collet.    
						

							ENGINE 24OVERHAUL
3.Lightly lubricate thetool with engine oil.
4. Insert pilotintovalve guide fromcombustion
chamber sideofcylinder headuntilshoulder of
pilot contacts guide.
5. Check thatcollet isfully inserted intovalve
guide andexpand colletagainst theguide
using asuitable tommybar.
6.Assemble the45°cutter, MS621 (exhaust
valves) and60°cutter, MS627 (inletvalves) to
tool LRT-12-501.
7. Position toolLRT-12-501 andappropriate
cutter tovalve seatinsert tobe refaced.
8. Using theAllen key,adjust position ofcutter so
that centre ofcutter contacts areaofseat insert
to be cut.   
						

							ENGINEOVERHAUL 25
9.Cut valve seatinsert usinglighthand pressure.
CAUTION: Removetheminimum amount
of material necessary toobtain correct
valve seatface.
10. Smear Prussian Bluetoseating faceofa
correctly groundvalve.
11. Insert valveintoguide andpress itfirmly,
without rotating ontoseat insert, remove valve.
12. Check thataneven lineofPrussian Bluehas
been transferred tocentre ofvalve seatinsert,
continue cuttingoperation asnecessary until
this has been achieved.
13. Upon completion, removealltraces ofswarf. Valve
seatinserts -renew
1. Remove originalvalveseatinsert taking care
not todamage cylinderhead.
2. Thoroughly cleanvalveseatinsert recess.
3. Heat cylinder headto65 °C.
WARNING: Takecarewhen handling hot
cylinder head.
4.Place cylinder headonbed ofhand press and
using asuitable mandrel, pressreplacement
seat insert intorecess.
5. Allow cylinder headtoair cool.
6. Check thatseat insert isseated squarely in
recess.    
						

							ENGINE 26OVERHAUL
Lapping-in
valves
1. Lap each valve toits seat using grinding paste.
2. Apply Prussian Bluetovalve seatinsert. Insert
valve intoguide andpress itfirmly, without
rotating ontoseat.
3. Remove valveandcheck thatacontinuous,
even lineofPrussian Bluehasbeen
transferred tovalve face,continue lapping-in
valve asnecessary.
NOTE: Linedoes nothave tobe across
whole widthofvalve face.
4. Remove alltraces ofgrinding pasteon
completion.
5. Check valveheadstand downofeach valve. Valve
headstand down-checking
1. Insert eachvalve intoitsrespective guide.
2. Using astraight edgeandfeeler gauges, check
and record standdownofeach valve head.
3. Compare figuresobtained withthose given
below. Ifany valve headhasastand down
outside thatspecified, valveand/or seatinsert
must bereplaced.
Valve headstand down:
Inlet valve A= 0.81 to1.09 mm
Exhaust valveB= 0.86 to1.14 mm   
						

							ENGINEOVERHAUL 27
Valves
andsprings -refit
1. Lubricate valvestems, guides, springseats,
valve springs, springcupsandcollets with
engine oil.
2. Lubricate newvalve stemoilseals withengine
oil and fitto valve guides.
3. Fitspring seat,insert valveintoitsrespective
guide, fitvalve spring andspring cup.
4. Compress valvespring usingtoolLRT-12-034
and fitcollets.
5. Remove toolLRT-12-034.
6. Tap spring cupwith asoft mallet toensure that
collets arecorrectly seated.
7. Repeat aboveprocedures forremaining
valves. Cylinder
headgasket selection
CAUTION: Newcylinder headgasket
should besame thickness asthe original.
If, however, cylinderhead,pistons or
crankshaft havebeen replaced, itwill be
necessary tocheck piston standproud inorder
to determine thecorrect thickness ofgasket.
1. Position amagnetic baseDTItocylinder block
top face adjacent tonumber 1cylinder bore.
2. Position stylusofgauge tocylinder blocktop
face onedge ofnumber 1cylinder bore;zero
gauge.
3. Rotate crankshaft inaclockwise directionuntil
numbers 1and 4pistons areatTDC.
4. Position stylusofDTI gauge nearedge of
piston crown, measure andrecord number 1
piston standproud. Measurement mustbe
taken atfront andrear ofpiston andhighest
protrusion figurerecorded.
5. Repeat aboveprocedures forremaining
pistons.   
						

							ENGINE
28 OVERHAUL
6.
From allofthe readings obtained, determine
highest protrusion figureandselect the
appropriate cylinderheadgasket.
Protrusion 0.50to0.60 mm-select gasket with
1 identification hole.
Protrusion 0.61to0.70 mm-select gasket with
2 identification holes.
Protrusion 0.71to0.80 mm-select gasket with
3 identification holes.
Protrusion 0.81to0.90 mm-select gasket with
0 identification holes.
NOTE:Identification holesarelocated on
the edge ofthe gasket.
7. Remove DTI.
8. Rotate crankshaft inaclockwise directionuntil
all pistons arehalf-way upcylinder bores. Cylinder
head-refit
1. Ensure thatmating facesofcylinder headand
block areclean anddryand that2locating
dowels arefitted incylinder block.
2. Lubricate threadsofnew cylinder headbolts
with engine oil.
3. Check thatcylinder headboltholes incylinder
block areclean anddry.
4. Rotate crankshaft inaclockwise directionuntil
pistons arehalf-way upcylinder bores.
5. Position theselected cylinderheadgasket on
cylinder blockensuring thatword TOP is
facing upwards.
6. Using assistance, fitcylinder headensuring
that itis located ondowels.