Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

							ENGINEOVERHAUL 29
7.Fitcylinder headboltsofthe correct lengthin
positions shown.
CAUTION: Donot drop bolts intocylinder
block.
8. Tighten boltsuntilboltheads justcontact
cylinder head.
9.Using sequence shown,tightencylinder head
bolts to40 Nm.    
						

							ENGINE 30OVERHAUL
10.Assemble degreeplateLRT-12-007 toa
torque wrench orextension bar.
11. Make asuitable pointerfromwelding rodand
attach itto the rocker shaftpedestal bolthole
adjacent tonumber 1cylinder headbolt.
12. Using sequence shown,tightencylinder head
bolts afurther 60°.
NOTE: Re-position thepointer as
necessary toenable degree oftightening
to be measured.
13. Using sequence shown,tighteneachbolta
further 60°.
CAUTION: Boltsmustbetightened in
sequence 60°at atime -never 120°in one
operation.
14. Using sequence shown,tightenboltsnumbers
1, 2,7,8,9,10, 15,16,17and 18afurther
20 °.
15. Remove pointer.
16.Position anew thermostat housinggasketto
cylinder head.
17. Fitthermostat housing,fitbolts andtighten to
25 Nm.
18. Position thermostat inhousing.
19. Fitcoolant outletelbow, fitbolts andtighten to
25 Nm.
20. Position enginefrontlifting bracket tocylinder
head, fit2bolts andtighten to25 Nm.
21. Fitfuel injectors.
22. Fitglow plugs.
23. Fitrocker shaftassembly.   
						

							ENGINEOVERHAUL 31
TIMING
BELTREAR COVER ANDOILPUMP
Timing beltrear cover -remove
1. Remove timingbelt,tensioner andgears.
2. Remove fuelinjection pump.
3. Remove sumpandoilpick-up pipe.
4.Using sequence shown,progressively slacken
then remove boltssecuring timingbeltrear
cover; remove cover.
5. Remove anddiscard gasket.
6. Remove anddiscard camshaft andcrankshaft
front oilseals. Oil
pump andoilpressure reliefvalve -remove
Oil pump
1.Make suitable alignment marksbetween oil
pump andtiming beltrear cover.
2. Progressively slackenthenremove 7screws
securing oilpump cover.
3. Remove oilpump cover.
4. Make suitable alignment marksbetween oil
pump innerandouter rotors andouter rotor
and timing beltrear cover.    
						

							ENGINE 32OVERHAUL
Oil
pressure reliefvalve
1.Remove plugretaining oilpressure reliefvalve.
2. Withdraw springandplunger. Inspecting
components
1.Check rotorclearances.
A -Outer rotortohousing =0.025 to0.075 mm
B -Inner rotortoouter rotor=0.025 to0.075
mm C -Rotor end-float =0.026 to0.135 mm
2. Remove innerandouter rotors.
3. Check rotorsfordamage, wearandscoring.
4. Check oilpump coverforwear andscoring.
5. Check oilpressure reliefvalve spring free
length is68.0 mm.
6. Check plunger andrelief valve boreforwear
and scoring.
7. Clean alltraces ofsealant fromoilpump cover
using solvent fromkitGUG 705548GM.
8. Remove alltraces ofsealant fromrelief valve
plug threads inoil pump body.
CAUTION: Donot use atap.   
						

							ENGINEOVERHAUL 33
Oil
pump andoilpressure reliefvalve -refit
Oil pump
1. Thoroughly cleantiming beltrear cover,
remove alltraces ofgasket usingsuitable
gasket removal sprayandaplastic scraper.
Remove alltraces ofsealant usingsolvent
from kitGUG 705548GM.
2. Ensure oilpump coverscrew holesareclean
and dry.
3. Clean oilpump rotors andrecess, lubricate
rotors andrecess withengine oil.
CAUTION: Ensurealignment marksmade
during dismantling arenot erased.
4. Position innerandouter rotors inhousing
ensuring thatreference marksarealigned.
5. Apply beadofsealant fromkittoouter edgeof
oil pump cover, fitcover tohousing ensuring
that reference marksarealigned.
6. Fitoilpump cover, fitand progressively tighten
7 screws.
7. Check thatpump rotates freely. Oil
pressure reliefvalve
1. Thoroughly cleanoilpressure reliefvalve
plunger, springandrelief valve borethen
lubricate components withengine oil.
2. Insert plunger andspring intobore.
3. Smear threads ofrelief valve plugwithLoctite
577.
4. Fitplug andtighten to17 Nm.  
						

							ENGINE 34OVERHAUL
Timing
beltrear cover -refit
1. Remove alltraces ofgasket material from
cylinder blockusing suitable gasketremoval
spray andaplastic scraper.
2.Screw 2slave guide studsintocylinder block.
3. Fitnew gasket overguide studs.
4.Note position ofoil pump driveflatson
crankshaft.
5. Rotate oilpump innerrotortoalign withdrive
flats oncrankshaft andposition timingbeltrear
cover onguide studs.
6. Fittiming beltrear cover.
CAUTION: Donot remove guidestudsat
this stage.
7. Fit8bolts ofthe correct lengthinpositions
shown, remove guidestudsandfitremaining 2
bolts.   
						

							ENGINEOVERHAUL 35
8.Using sequence shown,tightenboltsto25 Nm.
9. Fitoilpick-up pipeandsump.
10. Lubricate anew crankshaft frontoilseal with
engine oil.
11.Fitoilseal using toolLRT-12-079.
12. Lubricate anew camshaft oilseal withengine
oil.
13. Fitoilseal using toolLRT-12-082.
14. Fitfuel injection pump.
15. Fittiming belt,tensioner andgears.     
						

							ENGINE 36OVERHAUL
OIL
FILTER HEAD
Remove
1. Remove anddiscard oilfilter element.
2. Remove 4bolts securing filterhead tocylinder
block.
3. Remove filterhead, remove anddiscard
gasket. Thermostatic
valve-remove
1. Secure oilfilter head inasoft-jawed vicewith
thermostatic valvevertically upwards.
2. Remove 2bolts securing thermostatic valve
extension housingtooil filter head.
3. Remove extension housing,removeand
discard Oring.
4. Withdraw thermostatic valveandspring.
CAUTION: Donot separate valvefrom
spring.   
						

							ENGINEOVERHAUL 37
Inspecting
components
1. Check thermostatic valvespring fordistortion
and corrosion.
CAUTION: Donot separate valvefrom
spring.
2. Check valveforcorrosion, seatingfacesof
valve andextension housingfordamage and
pitting; replace valveasan assembly.
3. Check valveboreforcorrosion. Lightcorrosion
must beremoved fromvalve boreusing grade
600 emery clothsoaked inoil.
4. Check oilpassages inoil filter head areclear. Thermostatic
valve-refit
1. Secure oilfilter head inasoft-jawed vicewith
thermostatic valveborevertically upwards.
2.Lubricate anew Oring with engine oiland fit
to thermostatic valveextension housing.
3. Lubricate thermostatic valveandbore with
engine oil.
4. Fitthermostatic valveandspring.
5. Position extension housingtooil filter head
ensuring thatthermostatic valveispositioned
centrally inhousing.
6. Fitand progressively fingertighten 2bolts
ensuring thatthermostatic valveremains
correctly positioned inextension housing.
7. Tighten boltsto9Nm.   
						

							ENGINE 38OVERHAUL
Oil
filter head -refit
1. Remove alltraces ofgasket fromoilfilter head
and cylinder blockusing suitable gasket
removal sprayandaplastic scraper.
2.Smear anew gasket withengine oiland
position onoilfilter head.
3. Fitoilfilter head, fit4bolts andtighten to45
Nm.
4. Smear sealing ringofnew oilfilter element with
engine oiland fitto oil filter head.
5. Plug open pipeconnections toprevent ingress
of dirt. FUEL
INJECTION PUMP
Remove 1. Remove timingbelt.
2. Remove fuelpipes frompump andinjectors.3.Ensure thattiming pinLRT-12-045 isinserted
in injection pumpgearhubplate andinjection
pump hub.
4. Remove 3bolts securing hubandinjection
pump geartoinjection pump,remove timing
pin LRT-12-045 andgear.
CAUTION: Donot remove nutsecuring
hub topump.