Land Rover 300tdi Diesel Engine Overhaul 1997 Bookmarks Rover Manual

							ENGINE
OVERHAUL39
5.Remove 3 bolts securing mounting bracket and
baffle plate to cylinder block.
6.Remove 2 bolts securing mounting bracket to
injection pump, remove bracket.
7.Remove banjo bolt securing fuel spill return
pipe to injection pump, discard sealing
washers.
CAUTION: Plug open connections to
prevent ingress of dirt.
8.Remove 3 nuts securing injection pump to
timing belt rear cover, remove injection pump. 
						

							ENGINE
40
OVERHAUL Refit
1.Position injection pump to timing belt rear
cover, fit nuts and tighten to 25 Nm.
2.Fit fuel spill return pipe, fit banjo bolt and 2 new
sealing washers.
3.Tighten banjo bolt to 25 Nm.
4.Position mounting bracket to injection pump
and cylinder block, fit and finger tighten bolts.
5.Tighten mounting bracket bolts to 25 Nm in the
following order:
Mounting bracket to cylinder block
Mounting bracket to injection pump
6.Fit fuel pipes.
7.Position injection pump gear and hub plate to
injection pump hub ensuring that cut-out in hub
plate is aligned with timing pin hole in pump
hub.
8.Fit 3 bolts, position slot in gear mid-way under
bolt heads, lightly tighten bolts.
NOTE: Do not fit bolts through elongated
slots in hub plate. Bolts are fully tightened
after timing belt has been adjusted.
9.Insert timing pinLRT-12-045in hub plate and
injection pump hub.
10.Fit and tension timing belt.FUEL LIFT PUMP
Remove
1.Disconnect fuel delivery pipe from fuel lift
pump, discard sealing washers.
CAUTION: Plug open connections to
prevent ingress of dirt. 
						

							ENGINE
OVERHAUL41
2.Remove 2 bolts securing fuel lift pump to
cylinder block, remove pump, gasket, spacer
and 2nd gasket.
3.Discard gaskets.Refit
1.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Position new gaskets and spacer to fuel lift
pump.
3.Fit fuel lift pump ensuring that operating lever
is correctly positioned on camshaft.
4.Fit bolts and tighten to 25 Nm.
5.Position fuel delivery pipe to fuel lift pump, fit
banjo bolt and 2 new sealing washers.
CAUTION: Do not fully tighten banjo bolt
until pipe is connected to fuel filter. 
						

							ENGINE
42
OVERHAUL FUEL INJECTORS
Remove
1.Disconnect each pair of fuel pipes from fuel
injection pump and injectors.
2.Remove banjo bolt securing fuel spill return
pipes to injector, remove and discard 2 sealing
washers.
CAUTION: Plug broken connections to
prevent ingress of dirt.
3.Remove nut securing injector clamp, remove
clamp.
4.Remove injector, remove and discard sealing
washer.
WARNING: Do not attempt to remove
injectors using engine compression,
either use an open ended spanner on
injector body and rotate injector until it is
released or use a slide hammer and suitable
adaptor.
5.Repeat above procedures to remove remaining
injectors. 
						

							ENGINE
OVERHAUL43
Refit
1.Clean all traces of carbon from injector ports.
2.Fit a new sealing washer to injector, insert
injector into port ensuring that spill return banjo
bolt hole faces away from cylinder head.
3.Position injector clamp to injector and cylinder
head stud ensuring that raised pip on concave
face of clamp faces upwards.
4.Fit and tighten injector clamp nut to 25 Nm.
5.Position spill return pipes to injector, fit banjo
bolt and 2 new sealing washers.
6.Tighten banjo bolt to 10 Nm.
7.Repeat above procedures for remaining
injectors.
8.Position fuel pipes to injector and fuel injection
pump, tighten connections.GLOW PLUGS
Remove
1.Remove nut and washer securing harness to
glow plug, release harness from plug.
2.Remove glow plug.
3.Repeat above procedures for remaining plugs.
Refit
1.Fit glow plug and tighten to 20 Nm.
2.Connect harness to glow plug, fit and tighten
nut.
3.Repeat above procedures for remaining plugs. 
						

							ENGINE
44
OVERHAUL BRAKE SERVO VACUUM PUMP
Remove
1.Ensure that number 1 piston is at TDC.
CAUTION: Rotate crankshaft in a
clockwise direction.
2.Noting their fitted positions, progressively
slacken 5 bolts until all loading is removed from
vacuum pump piston.
NOTE: The sixth bolt was removed during
air cleaner bracket removal.
3.Remove bolts.
4.Remove vacuum pump, remove and discard
gasket.Refit
1.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Ensure number 1 piston is still at TDC.
3.Fit vacuum pump, fit and finger tighten 5 bolts
in their original positions.
NOTE: The sixth bolt is fitted when air
cleaner bracket is fitted.
4.Tighten bolts progressively by diagonal
selection to 25 Nm. 
						

							ENGINE
OVERHAUL45
SUMP, OIL PICK-UP AND DRAIN PIPES
Sump - remove
1.Using sequence shown, progressively slacken,
then remove 22 bolts securing sump to cylinder
block.
2.Remove sumpOil pick-up and drain pipes - remove1.Remove bolt securing oil pick-up pipe flange to
timing belt rear cover.
2.Remove 4 bolts securing oil pick-up and drain
pipes to cylinder block and main bearing cap
bolts.
3.Remove oil pick-up and drain pipes.
4.Remove and discard O ring and gasket. 
						

							ENGINE
46
OVERHAUL Oil pick-up and drain pipes - refit
1.Clean oil pick-up and drain pipes and strainer,
remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Ensure bolt holes in timing belt rear cover,
cylinder block and main bearing cap bolts are
clean and dry and that all traces of Loctite are
removed from holes in main bearing cap bolts.
CAUTION: Do not use a tap to remove
Loctite from bolt holes.
3.Lubricate a new O ring with engine oil and fit
to oil pick-up pipe.
4.Position a new gasket to cylinder block.
5.Position oil pick-up pipe to timing belt rear
cover and drain pipe to cylinder block.
6.Apply Loctite 242E to threads of oil pick-up
pipe to main bearing cap bolts, fit bolts and
tighten to 9 Nm.
7.Fit bolts securing oil pick-up and drain pipes to
cylinder block and timing belt rear cover,
tighten to 25 Nm. 
						

							ENGINE
OVERHAUL47
Sump - refit
1.Clean sump and remove all traces of sealant
using solvent from kit GUG 705548GM.
2.Apply a 2 mm bead of Hylomar Instant Gasket
302 (black) to sump flange ensuring that
sealant is applied inboard of bolt holes.
3.Position sump to cylinder block.
CAUTION: Sump must be fitted within 30
minutes of applying sealant.
4.Fit 22 sump bolts and tighten in sequence
shown to 25 Nm.
5.Check that sump drain plug is tightened to 35
Nm.FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Screw 2 slave 8 mm bolts into flywheel. 
						

							ENGINE
48
OVERHAUL
2.Temporarily fit crankshaft pulley.
3.Position toolLRT-12-080to crankshaft pulley,
secure with 4 bolts.
4.Restrain crankshaft pulley using tool
LRT-12-080and remove 8 bolts securing
flywheel; discard locking plate - if fitted.
5.Using assistance, remove flywheel using 2
slave bolts.
NOTE: Dowel located.