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
re-tension timing belt.
10.Tighten tensioner bolt to 45 Nm.
11.Fit timing pinLRT-12-045into fuel injection
pump gear hub plate and pump hub. If timing
pin cannot be inserted, slacken injection pump
gear bolts, rotate pump shaft using shaft nut
until pin slides easily into pump hub, Tighten
bolts to 25 Nm.
12.Tighten camshaft gear bolt to 80 Nm.
13.Remove timing pin and flywheel/drive plate
locking tools.
14.Fit plug to flywheel housing, tighten to 12 Nm.
15.Remove crankshaft pulley bolt.
16.Support timing belt front cover on suitable
blocks of wood.
17.Smear a new crankshaft oil seal with engine
oil.
18.Using toolLRT-12-077,fit oil seal from inside
face of front cover.
19.Fit a dry, new gasket to timing belt rear cover.
20.Position timing belt front cover to rear cover.
21.Fit bolts of the correct length in positions
shown. 
						

							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.
8.Working from the centre outwards,
progressively slacken then remove 3 nuts and
2 bolts securing rocker shaft pedestals to
cylinder head.
CAUTION: Insert a slave bolt into
pedestals 1 and 5 to prevent components
sliding off shaft.
9.Remove rocker shaft assembly. 
						

							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 for wear. Pay particular
attention to ball ends, replace any showing
signs of flattening on the ball or damage to
threads.
6.Check that each nut runs freely on adjusting
screw threads.
7.Check each push rod for signs of wear and for
straightness, replace as necessary.
8.Check valve caps for signs of wear, replace as
necessary.
9.Check rocker arm bushes for scoring and
wear.
10.Assemble each rocker arm to its fitted location
on rocker shaft and check clearance of bush to
shaft does not exceed 0.12 mm.
11.If clearance exceeds figure given, bushes must
be replaced.Rocker arm bushes - replace
1.Support rocker arm on bed of hand press.
2.Using a suitable piloted mandrel, press bush
out of rocker arm.
3.Lubricate replacement bush with engine oil and
press into rocker arm ensuring that lubrication
holes in bush and arm are aligned.
4.Check that lubrication holes in each rocker arm
are clear.
5.Check that lubrication holes in rocker shaft are
clear.
6.Check spacers and washers for wear, replace
as necessary. 
						

							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 arm until ball end is flush with
underside of arm; fit but do not tighten
locknuts.
3.Lubricate valve pads with engine oil and fit to
their original positions.
4.Position rocker shaft to cylinder head, fit but do
not tighten 3 nuts.
5.Remove slave bolts from pedestals 1 and 5, fit
but do not tighten 2 bolts.
6.Locate each push rod in turn beneath its
respective tappet adjusting screw and tighten
each screw until ball end locates in recess in
push rod.
7.Working from the centre outwards,
progressively tighten 3 nuts and 2 bolts to 5
Nm. 
						

							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.
17.Thoroughly clean mating faces of rocker cover
and cylinder head, remove all traces of gasket
material using gasket removal spray and a
plastic scraper. 
						

							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 valve.
Valve clearance - all valves = 0.20 mm
3.Tighten tappet adjusting screw locknut when
clearance is correct.
4.Adjust the remaining valve clearances in the
following sequence:
Adjust number 3 clearance with number 6
valve fully open
Adjust number 5 clearance with number 4
valve fully open
Adjust number 2 clearance with number 7
valve fully open
Adjust number 8 clearance with number 1
valve fully open
Adjust number 6 clearance with number 3
valve fully open
Adjust number 4 clearance with number 5
valve fully open
Adjust number 7 clearance with number 2
valve fully open
5.Upon completion, re-check all clearances and
adjust as necessary. 
						

							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 unless a
replacement cylinder head, crankshaft and/or
pistons are fitted.
- See Cylinder head gasket
selection.
7.Discard cylinder head gasket.
8.Remove 2 bolts securing coolant outlet elbow.
9.Remove coolant outlet elbow.
10.Remove thermostat from housing.
11.Remove 4 bolts securing thermostat housing to
cylinder head, remove housing.
12.Remove and discard gasket.
13.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.