Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

ENGINE
OVERHAUL9
5.Check that timing pinLRT-12-045moves
freely in and out of injection pump hub, if pin
does not move freely, slacken 3 bolts, move
gear slightly and re-check.
6.When timing pin moves freely, tighten 3 bolts
to 25 Nm.
7.Remove timing pinLRT-12-045and
flywheel/drive plate locking toolLRT-12-044.
8.Rotate crankshaft twice in a clockwise direction
using crankshaft pulley bolt until flywheel/drive
plate locking toolLRT-12-044can be refitted.
9.Slacken timing belt tensioner securing bolt and...

ENGINE
10
OVERHAUL
22.Tighten bolts in sequence shown to 25 Nm.
23.Lightly oil crankshaft spigot, fit Woodruff key
and crankshaft pulley.
24.Position toolLRT-12-080to crankshaft pulley,
retain tool using 4 bolts.
25.Fit crankshaft pulley flange head bolt.
26.Restrain crankshaft and tighten bolt to 80
Nm,then further 90.°
27.Remove toolLRT-12-080. 

ENGINE
OVERHAUL11
ROCKER SHAFT
Remove
1.Disconnect breather hoses from crankcase
breather cyclone unit.
2.Remove bolt securing cyclone unit to rocker
cover.
3.Remove cyclone unit, remove and discard O
ring.
4.Disconnect breather hoses from cylinder block
and rocker cover.
5.Remove 3 flange nuts securing rocker cover,
recover sealing washers.
6.Remove rocker cover, remove and discard
gasket.
7.Slacken locknut on each tappet adjusting
screw, slacken adjusting screws until they are
clear of push rods....

ENGINE
12
OVERHAUL
10.Withdraw push rods.
11.Remove valve caps.
CAUTION: Keep push rods and valve caps
in their fitted order.Rocker shaft - dismantling
1.Suitably identify each component to its fitted
position.
2.Remove locknut and tappet adjusting screw
from each rocker.
3.Remove slave bolt and pedestal from end of
rocker shaft.
4.Remove washer, rocker arm and spacer
followed by second rocker arm, spacer and
pedestal.
5.Repeat above procedures until all components
are removed. 

ENGINE
OVERHAUL13
Inspecting components
1.Measure and record diameter of rocker shaft at
one of the pedestal locations.
2.Measure and record diameter of rocker shaft at
each of the rocker arm locations.
3.Compare measurements obtained and
calculate difference between diameters. If wear
at any rocker shaft location exceeds 0.025 mm,
a new rocker shaft must be fitted.
4.Check rocker arm pads for signs of wear,
replace rocker arms as necessary.
5.Check threads and ball ends of each tappet
adjusting screw...

ENGINE
14
OVERHAUL Rocker shaft - assembling
1.Lubricate all components with engine oil.
2.Assemble rocker arms, spacers, washers and
pedestals to rocker shaft ensuring that they are
in their original fitted positions.
3.Retain pedestals 1 and 5 with slave bolts.Rocker shaft - refit
1.Lubricate push rods with engine oil and fit to
their original positions. Ensure that ball end of
each push rod is correctly located in each cam
follower slide.
2.Screw each tappet adjusting screw into its
respective rocker...

ENGINE
OVERHAUL15
8.Make a suitable pointer from welding rod and
position it to number 1 pedestal stud.
9.Temporarily fit a nut to secure pointer to stud.
10.Assemble degree plateLRT-12-007to a
suitable torque wrench or extension bar.
11.Tighten the centre pedestal nut a further 50°.
12.Tighten 2 pedestal bolts and number 5
pedestal nut a further 50°.
13.Remove pointer and secure it to number 5
pedestal stud.
14.Tighten number 1 pedestal nut a further 50°.
15.Remove pointer.
16.Adjust valve clearances....

ENGINE
16
OVERHAUL
18.Check sealing washers for damage or
distortion, replace as necessary.
19.Position a new gasket - dry to rocker cover.
20.Position rocker cover to cylinder head, fit 3
flange nuts and working from centre outwards,
tighten to 10 Nm.
21.Lubricate a new O ring with engine oil and fit
to crankcase breather cyclone unit.
22.Fit cyclone unit to rocker cover, fit bolt and
tighten to 9 Nm.
23.Connect breather hoses to cyclone unit, rocker
cover and cylinder block. 

ENGINE
OVERHAUL17
VALVE CLEARANCES - ADJUST
CAUTION: To prevent possibility of
damage to cam follower seatings, it is
essential that ball ends of tappet adjusting
screws are seated in recess in push rods and
that ball end of each push rod is correctly
located in cam follower slide.
1.Rotate crankshaft by means of crankshaft
pulley bolt in a clockwise direction until number
8 valve ( counting from front of engine ) is fully
open.
2.Using feeler gauges and a screwdriver, adjust
clearance of number 1...

ENGINE
18
OVERHAUL CYLINDER HEAD
Remove
1.Remove rocker shaft.
2.Remove fuel injectors.
3.Remove glow plugs.
4.Using sequence shown, progressively slacken
then remove and discard 18 bolts securing
cylinder head.
5.Using assistance, remove cylinder head.
NOTE: Dowel located.
6.Remove cylinder head gasket.
CAUTION: Identify cylinder head gasket
thickness by the number of holes in the
edge of the gasket between numbers 3
and 4 injector ports. Replacement gasket must
be of the same thickness as the original...