Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

ENGINEOVERHAUL 9
5.Check thattiming pinLRT-12-045 moves
freely inand outofinjection pumphub,ifpin
does notmove freely, slacken 3bolts, move
gear slightly andre-check.
6. When timing pinmoves freely,tighten 3bolts
to 25 Nm.
7. Remove timingpinLRT-12-045 and
flywheel/drive platelocking toolLRT-12-044.
8. Rotate crankshaft twiceinaclockwise direction
using crankshaft pulleyboltuntil flywheel/drive
plate locking toolLRT-12-044 canberefitted.
9. Slacken timingbelttensioner securingboltand
re-tension...

ENGINE 10OVERHAUL
22.Tighten boltsinsequence shownto25 Nm.
23. Lightly oilcrankshaft spigot,fitWoodruff key
and crankshaft pulley.
24.Position toolLRT-12-080 tocrankshaft pulley,
retain toolusing 4bolts.
25. Fitcrankshaft pulleyflange headbolt.
26. Restrain crankshaft andtighten boltto80
Nm,then further90.°
27. Remove toolLRT-12-080.   

ENGINEOVERHAUL 11
ROCKER
SHAFT
Remove
1. Disconnect breatherhosesfromcrankcase
breather cycloneunit.
2. Remove boltsecuring cycloneunittorocker
cover.
3. Remove cycloneunit,remove anddiscard O
ring.
4. Disconnect breatherhosesfromcylinder block
and rocker cover.
5.Remove 3flange nutssecuring rockercover,
recover sealingwashers.
6. Remove rockercover,remove anddiscard
gasket.
7. Slacken locknutoneach tappet adjusting
screw, slacken adjusting screwsuntilthey are
clear ofpush rods.
8. Working fromthecentre...

ENGINE 12OVERHAUL
10.Withdraw pushrods.
11. Remove valvecaps.
CAUTION: Keeppushrodsandvalve caps
in their fitted order. Rocker
shaft-dismantling
1. Suitably identifyeachcomponent toits fitted
position.
2. Remove locknutandtappet adjusting screw
from each rocker.
3. Remove slaveboltand pedestal fromendof
rocker shaft.
4. Remove washer,rockerarmandspacer
followed bysecond rockerarm,spacer and
pedestal.
5. Repeat aboveprocedures untilallcomponents
are removed.   

ENGINEOVERHAUL 13
Inspecting
components
1. Measure andrecord diameter ofrocker shaftat
one ofthe pedestal locations.
2. Measure andrecord diameter ofrocker shaftat
each ofthe rocker armlocations.
3. Compare measurements obtainedand
calculate difference betweendiameters. Ifwear
at any rocker shaftlocation exceeds 0.025mm,
a new rocker shaftmustbefitted.
4. Check rockerarmpads forsigns ofwear,
replace rockerarmsasnecessary.
5. Check threads andballends ofeach tappet
adjusting screwforwear. Payparticular...

ENGINE 14OVERHAUL
Rocker
shaft-assembling
1. Lubricate allcomponents withengine oil.
2. Assemble rockerarms,spacers, washersand
pedestals torocker shaftensuring thatthey are
in their original fittedpositions.
3. Retain pedestals 1and 5with slave bolts. Rocker
shaft-refit
1. Lubricate pushrodswithengine oiland fitto
their original positions. Ensurethatballend of
each pushrodiscorrectly locatedineach cam
follower slide.
2. Screw eachtappet adjusting screwintoits
respective rockerarmuntil ballend isflush...

ENGINEOVERHAUL 15
8.Make asuitable pointerfromwelding rodand
position itto number 1pedestal stud.
9. Temporarily fitanut tosecure pointer tostud.
10. Assemble degreeplateLRT-12-007 toa
suitable torquewrench orextension bar.
11. Tighten thecentre pedestal nutafurther 50°.
12. Tighten 2pedestal boltsandnumber 5
pedestal nutafurther 50°.
13. Remove pointerandsecure itto number 5
pedestal stud.
14. Tighten number 1pedestal nutafurther 50°.
15. Remove pointer.
16. Adjust valveclearances.
17. Thoroughly...

ENGINE 16OVERHAUL
18.Check sealing washers fordamage or
distortion, replaceasnecessary.
19. Position anew gasket -dry torocker cover.
20. Position rockercovertocylinder head,fit3
flange nutsandworking fromcentre outwards,
tighten to10 Nm.
21. Lubricate anew Oring with engine oiland fit
to crankcase breathercycloneunit.
22. Fitcyclone unittorocker cover,fitbolt and
tighten to9Nm.
23. Connect breatherhosestocyclone unit,rocker
cover andcylinder block.   

ENGINEOVERHAUL 17
VALVE
CLEARANCES -ADJUST
CAUTION: Toprevent possibility of
damage tocam follower seatings, itis
essential thatballends oftappet adjusting
screws areseated inrecess inpush rodsand
that ballend ofeach push rodiscorrectly
located incam follower slide.
1. Rotate crankshaft bymeans ofcrankshaft
pulley boltinaclockwise directionuntilnumber
8 valve (counting fromfrontofengine )is fully
open.
2. Using feelergauges andascrewdriver, adjust
clearance ofnumber 1valve.
Valve clearance -all valves...

ENGINE 18OVERHAUL
CYLINDER
HEAD
Remove 1. Remove rockershaft.
2. Remove fuelinjectors.
3. Remove glowplugs.
4.Using sequence shown,progressively slacken
then remove anddiscard 18bolts securing
cylinder head.
5. Using assistance, removecylinder head.
NOTE:Dowellocated.
6. Remove cylinderheadgasket.
CAUTION: Identifycylinder headgasket
thickness bythe number ofholes inthe
edge ofthe gasket between numbers 3
and 4injector ports.Replacement gasketmust
be ofthe same thickness asthe original unlessa...