Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual
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ENGINEOVERHAUL 39 5.Remove 3bolts securing mounting bracketand baffle platetocylinder block. 6. Remove 2bolts securing mounting bracketto injection pump,remove bracket. 7.Remove banjoboltsecuring fuelspill return pipe toinjection pump,discard sealing washers. CAUTION: Plugopen connections to prevent ingressofdirt. 8. Remove 3nuts securing injectionpumpto timing beltrear cover, remove injection pump.
ENGINE 40OVERHAUL Refit 1. Position injection pumptotiming beltrear cover, fitnuts andtighten to25 Nm. 2. Fitfuel spill return pipe,fitbanjo boltand 2new sealing washers. 3. Tighten banjoboltto25 Nm. 4. Position mounting brackettoinjection pump and cylinder block,fitand finger tighten bolts. 5. Tighten mounting bracketboltsto25 Nm inthe following order: Mounting brackettocylinder block Mounting brackettoinjection pump 6. Fitfuel pipes. 7.Position injection pumpgearandhubplate to injection pumphubensuring thatcut-out inhub plate isaligned withtiming pinhole inpump hub. 8. Fit3bolts, position slotingear mid-way under bolt heads, lightlytighten bolts. NOTE: Donot fitbolts through elongated slots inhub plate. Boltsarefully tightened after timing belthasbeen adjusted. 9. Insert timing pinLRT-12-045 inhub plate and injection pumphub. 10. Fitand tension timingbelt. FUEL LIFTPUMP Remove 1. Disconnect fueldelivery pipefrom fuellift pump, discard sealingwashers. CAUTION: Plugopen connections to prevent ingressofdirt.
ENGINEOVERHAUL 41 2.Remove 2bolts securing fuelliftpump to cylinder block,remove pump,gasket, spacer and 2ndgasket. 3. Discard gaskets. Refit 1. Remove alltraces ofgasket usingsuitable gasket removal sprayandaplastic scraper. 2. Position newgaskets andspacer tofuel lift pump. 3. Fitfuel liftpump ensuring thatoperating lever is correctly positioned oncamshaft. 4. Fitbolts andtighten to25 Nm. 5. Position fueldelivery pipetofuel liftpump, fit banjo boltand 2new sealing washers. CAUTION: Donot fully tighten banjobolt until pipeisconnected tofuel filter.
ENGINE 42OVERHAUL FUEL INJECTORS Remove 1. Disconnect eachpairoffuel pipes fromfuel injection pumpandinjectors. 2.Remove banjoboltsecuring fuelspill return pipes toinjector, removeanddiscard 2sealing washers. CAUTION: Plugbroken connections to prevent ingressofdirt. 3. Remove nutsecuring injectorclamp,remove clamp. 4. Remove injector,removeanddiscard sealing washer. WARNING: Donot attempt toremove injectors usingengine compression, either useanopen ended spanner on injector bodyandrotate injector untilitis released oruse aslide hammer andsuitable adaptor. 5. Repeat aboveprocedures toremove remaining injectors.
ENGINEOVERHAUL 43 Refit 1. Clean alltraces ofcarbon frominjector ports. 2. Fitanew sealing washer toinjector, insert injector intoport ensuring thatspill return banjo bolt hole faces awayfromcylinder head. 3. Position injectorclamptoinjector andcylinder head studensuring thatraised piponconcave face ofclamp facesupwards. 4. Fitand tighten injector clampnutto25 Nm. 5. Position spillreturn pipestoinjector, fitbanjo bolt and 2new sealing washers. 6. Tighten banjoboltto10 Nm. 7. Repeat aboveprocedures forremaining injectors. 8. Position fuelpipes toinjector andfuelinjection pump, tighten connections. GLOW PLUGS Remove 1. Remove nutand washer securing harnessto glow plug, release harness fromplug. 2. Remove glowplug. 3. Repeat aboveprocedures forremaining plugs. Refit 1. Fitglow plugandtighten to20 Nm. 2. Connect harnesstoglow plug, fitand tighten nut. 3. Repeat aboveprocedures forremaining plugs.
ENGINE 44OVERHAUL BRAKE SERVOVACUUM PUMP Remove 1. Ensure thatnumber 1piston isat TDC. CAUTION: Rotatecrankshaft ina clockwise direction. 2.Noting theirfitted positions, progressively slacken 5bolts untilallloading isremoved from vacuum pumppiston. NOTE: Thesixth boltwas removed during air cleaner bracket removal. 3. Remove bolts. 4. Remove vacuumpump,remove anddiscard gasket. Refit 1. Remove alltraces ofgasket usingsuitable gasket removal sprayandaplastic scraper. 2. Ensure number 1piston isstill atTDC. 3. Fitvacuum pump,fitand finger tighten 5bolts in their original positions. NOTE:Thesixth boltisfitted when air cleaner bracket isfitted. 4. Tighten boltsprogressively bydiagonal selection to25 Nm.
ENGINEOVERHAUL 45 SUMP, OILPICK-UP ANDDRAIN PIPES Sump -remove 1. Using sequence shown,progressively slacken, then remove 22bolts securing sumptocylinder block. 2. Remove sump Oil pick-up anddrain pipes -remove1. Remove boltsecuring oilpick-up pipeflange to timing beltrear cover. 2. Remove 4bolts securing oilpick-up anddrain pipes tocylinder blockandmain bearing cap bolts. 3. Remove oilpick-up anddrain pipes. 4. Remove anddiscard Oring and gasket.
ENGINE 46OVERHAUL Oil pick-up anddrain pipes -refit 1. Clean oilpick-up anddrain pipes andstrainer, remove alltraces ofgasket usingsuitable gasket removal sprayandaplastic scraper. 2. Ensure boltholes intiming beltrear cover, cylinder blockandmain bearing capbolts are clean anddryand thatalltraces ofLoctite are removed fromholes inmain bearing capbolts. CAUTION: Donot use atap toremove Loctite fromboltholes. 3.Lubricate anew Oring with engine oiland fit to oil pick-up pipe. 4. Position anew gasket tocylinder block. 5. Position oilpick-up pipetotiming beltrear cover anddrain pipetocylinder block. 6. Apply Loctite 242Etothreads ofoil pick-up pipe tomain bearing capbolts, fitbolts and tighten to9Nm. 7. Fitbolts securing oilpick-up anddrain pipes to cylinder blockandtiming beltrear cover, tighten to25 Nm.
ENGINEOVERHAUL 47 Sump -refit 1. Clean sumpandremove alltraces ofsealant using solvent fromkitGUG 705548GM. 2. Apply a2m m bead ofHylomar InstantGasket 302 (black) tosump flange ensuring that sealant isapplied inboard ofbolt holes. 3. Position sumptocylinder block. CAUTION: Sumpmustbefitted within 30 minutes ofapplying sealant. 4.Fit22 sump boltsandtighten insequence shown to25 Nm. 5. Check thatsump drainplugistightened to35 Nm. FLYWHEEL ANDSTARTER RINGGEAR Flywheel -remove 1. Screw 2slave 8m m bolts intoflywheel.
ENGINE 48OVERHAUL 2.Temporarily fitcrankshaft pulley. 3. Position toolLRT-12-080 tocrankshaft pulley, secure with4bolts. 4. Restrain crankshaft pulleyusingtool LRT-12-080 andremove 8bolts securing flywheel; discardlockingplate-if fitted. 5. Using assistance, removeflywheel using2 slave bolts. NOTE: Dowellocated.