Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

ENGINE
OVERHAUL69
11.Assemble each big-end bearing cap less
bearing shells to its respective connecting rod.
12.Fit and tighten big-end bearing cap nuts to 59
Nm.
13.Slacken the nut on one side of connecting rod.
14.Using feeler gauges, check that there is no gap
between bearing cap and connecting rod on
the side of the cap with the slackened nut.
CAUTION: If clearance exists, connecting
rod must be replaced.
15.Remove nuts and big-end bearing caps.
CAUTION: Retain nuts and bearing caps
with their...

ENGINE
70
OVERHAUL Piston rings - checking
CAUTION: Prior to checking piston ring
gaps in cylinder bores, bores must be
inspected, measured and if reboring has
been carried out, the appropriate oversize
pistons and rings used.
1.Check fitted gap of each new piston ring in turn
with ring positioned half-way down cylinder
bore.
Fitted gap of rings in bores:
Top compression = 0.40 to 0.65 mm
2nd compression = 0.30 to 0.50 mm
Oil control rails = 0.30 to 0.60 mm
CAUTION: Ensure that piston rings are
suitably...

ENGINE
OVERHAUL71
6.Check ring to groove clearances:
Top compression = 0.167 to 0.232 mm
2nd compression = 0.05 to 0.08 mm
Oil control rails = 0.05 to 0.08 mm
7.If new ring to groove clearances are excessive,
new pistons must be fitted.Oil jet tubes - inspection
1.Check that oil passage in each oil jet tube is
clear.
2.Thoroughly clean banjo bolts.
3.Insert a piece of stiff wire in end of banjo bolt
and check that non-return valve can be
depressed to open position and returns to
closed position under...

ENGINE
72
OVERHAUL Pistons and connecting rods - refit
1.Position piston ring gaps at 60°to each other
and away from thrust side of piston (left hand
side of piston when viewed from front).
2.Slide suitable lengths of tubing over connecting
rod bolts.
3.Ensure cylinder bores are clean.
4.Lubricate pistons, rings and cylinder bores with
engine oil.
5.Compress piston rings using a suitable clamp.
6.Insert piston and connecting rod into cylinder
bore ensuring that piston is in its correct fitted
order and...

ENGINE
OVERHAUL73
Camshaft - remove
1.Remove oil jet tube.
2.Clean area around baffle plate.
3.Note fitted position of 3 bolts securing baffle
plate.
4.Remove 3 bolts securing baffle plate to
cylinder block, remove plate.
5.Remove and discard gasket.
CAUTION: Do not remove cam follower
guide retaining bolts until slides and
rollers have been removed, keep
components of each cam follower assembly in
their fitted order.
6.Using long nosed pliers, remove cam follower
slide.
7.Remove roller and suitably...

ENGINE
74
OVERHAUL
11.Remove 2 bolts securing camshaft thrust plate
to cylinder block, remove and discard plate.
12.Carefully withdraw camshaft taking care not to
drop end of camshaft on to bearings.Camshaft, bearings and cam followers -
inspection
1.Check camshaft cams and bearing journals for
overheating, wear and scoring, replace
camshaft if necessary.
2.If camshaft is replaced, new bearings must be
fitted.
3.Check timing gear drive pin for security.
4.Check camshaft bearings for overheating, wear
and...

ENGINE
OVERHAUL75
Camshaft - refit and check end-float
1.Remove all traces of gasket from baffle plate
and cylinder block using suitable gasket
removal spray and a plastic scraper.
2.Lubricate cams, journals and bearings with
engine oil.
3.Ensure thrust plate bolt holes in cylinder block
are clean and dry.
4.Carefully insert camshaft into cylinder block
taking care not to drop end of camshaft on to
bearings.
5.Fit a new thrust plate, fit bolts and tighten to 9
Nm.
6.Temporarily fit camshaft timing gear,...

ENGINE
76
OVERHAUL
15.Insert each cam follower guide into its original
location in the cylinder block.
16.Fit new retaining bolt, locate end of bolt in cam
follower guide.
17.Tighten bolt to 14 Nm.
18.Fit roller ensuring that reference mark made
during removal is towards front of cylinder
block.
19.Fit cam follower slide ensuring that word
FRONT or mark F is towards front of cylinder
block.
20.Repeat above procedures for remaining cam
follower assemblies.
21.Fit a dry, new gasket to baffle plate.
22.Fit...

ENGINE
OVERHAUL77
9.Check cylinder bore overall wear, measure at
several points from side to side, the largest
diameter recorded is the maximum wear.
Cylinder bore - standard = 90.47 mm
1st rebore oversize = 90.73 mm
2nd rebore oversize = 90.98 mm
Maximum wear = 0.177 mm
CAUTION: Do not de-glaze cylinder bores.
10.Cylinder bores which are worn in excess of
0.177 mm over the above bore sizes must be
rebored and the appropriate oversize pistons
and rings fitted.
CAUTION: Cylinder bores must be honed
to...

ENGINE
DATA, TORQUE & TOOLS1
ENGINE DATA
Rocker shaft
Rocker shaft wear - maximum 0.025 mm..................
Rocker arm shaft to bush clearance - maximum 0.12 mm....
Valve clearance - inlet and exhaust 0.20 mm..............
Oil pump
Outer rotor to housing clearance 0.025 to 0.075 mm................
Inner to outer rotor clearance 0.025 to 0.075 mm..................
Outer rotor end-float 0.026 to 0.135 mm.........................
Relief valve spring free length 68.0 mm..................
Cylinder head...