Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

							ENGINEOVERHAUL 69
11.Assemble eachbig-end bearingcapless
bearing shellstoits respective connecting rod.
12. Fitand tighten big-end bearingcapnuts to59
Nm.
13. Slacken thenutonone side ofconnecting rod.
14. Using feelergauges, checkthatthere isno gap
between bearingcapand connecting rodon
the side ofthe cap with theslackened nut.
CAUTION: Ifclearance exists,connecting
rod must bereplaced.
15. Remove nutsandbig-end bearingcaps.
CAUTION: Retainnutsandbearing caps
with their respective connecting rod
16. Repeat aboveprocedures forremaining
connecting rods. 17.
Lubricate gudgeonpinsandsmall endbushes
with engine oil.
18. Assemble eachconnecting rodand gudgeon
pin toits respective pistonensuring that
bearing tagrecess onconnecting rodison
correct sideofpiston.
19. Fitnew circlips toretain gudgeon pinsensuring
they arecorrectly seatedintheir grooves.   
						

							ENGINE 70OVERHAUL
Piston
rings-checking
CAUTION: Priortochecking pistonring
gaps incylinder bores,boresmustbe
inspected, measuredandifreboring has
been carried out,theappropriate oversize
pistons andrings used.
1.Check fittedgapofeach newpiston ringinturn
with ringpositioned half-waydowncylinder
bore. Fitted gapofrings inbores:
Top compression =0.40 to0.65 mm
2nd compression =0.30 to0.50 mm
Oil control rails=0.30 to0.60 mm
CAUTION: Ensurethatpiston ringsare
suitably identified withthecylinder borein
which theywere checked andthat they are
fitted tothe piston forthat cylinder bore.
2.Fitoilcontrol railsandspring topiston.
3. Fit2nd, narrow compression ringwith TOP
marking uppermost.
4. Fittop compression ringwith TOP marking
uppermost.
5. Check thatrings arefree torotate intheir
grooves.   
						

							ENGINEOVERHAUL 71
6.Check ringtogroove clearances:
Top compression =0.167 to0.232 mm
2nd compression =0.05 to0.08 mm
Oil control rails=0.05 to0.08 mm
7. Ifnew ringtogroove clearances areexcessive,
new pistons mustbefitted. Oil
jettubes -inspection
1. Check thatoilpassage ineach oiljet tube is
clear.
2. Thoroughly cleanbanjo bolts.
3. Insert apiece ofstiff wire inend ofbanjo bolt
and check thatnon-return valvecanbe
depressed toopen position andreturns to
closed position underspring pressure.
CAUTION: Ifnon-return valveisnot
working correctly, replacebanjobolt.
4. Check sealing washers fordamage, replaceas
necessary.   
						

							ENGINE 72OVERHAUL
Pistons
andconnecting rods-refit
1. Position pistonringgaps at60 °to each other
and away fromthrust sideofpiston (lefthand
side ofpiston whenviewed fromfront).
2. Slide suitable lengthsoftubing overconnecting
rod bolts.
3. Ensure cylinder boresareclean.
4. Lubricate pistons,ringsandcylinder boreswith
engine oil.
5.Compress pistonringsusing asuitable clamp.
6. Insert piston andconnecting rodinto cylinder
bore ensuring thatpiston isin its correct fitted
order andarrow onpiston crownistowards
front ofcylinder block.
7. Push piston intocylinder bore.
CAUTION: Ensurethatconnecting rodsdo
not contact cylinder bores.Donot pull
connecting rodsfullydown cylinder bores
at this stage.
8. Repeat aboveprocedures fornumbers 2and 3
pistons andconnecting rods. Oil
jettubes -refit
1. Position sealingwashers incylinder block.
2. Fitoiljet tubes totheir original locations.
3. Fitbanjo boltsandwashers, tightenboltsto17
Nm.   
						

							ENGINEOVERHAUL 73
Camshaft
-remove
1. Remove oiljet tube.
2. Clean areaaround baffleplate.
3. Note fitted position of3bolts securing baffle
plate.
4. Remove 3bolts securing baffleplateto
cylinder block,remove plate.
5. Remove anddiscard gasket.
CAUTION: Donot remove camfollower
guide retaining boltsuntilslides and
rollers havebeen removed, keep
components ofeach camfollower assembly in
their fitted order.
6. Using longnosed pliers,remove camfollower
slide.
7. Remove rollerandsuitably identifywhichside
of roller faces towards frontofcylinder block.
8. Remove anddiscard boltretaining cam
follower guide.
9. Remove camfollower guide.
10. Repeat aboveprocedures forremaining cam
follower assemblies.     
						

							ENGINE 74OVERHAUL
11.Remove 2bolts securing camshaft thrustplate
to cylinder block,remove anddiscard plate.
12. Carefully withdrawcamshaft takingcarenotto
drop endofcamshaft ontobearings. Camshaft,
bearingsandcam followers -
inspection
1. Check camshaft camsandbearing journals for
overheating, wearandscoring, replace
camshaft ifnecessary.
2. Ifcamshaft isreplaced, newbearings mustbe
fitted.
3. Check timinggeardrive pinforsecurity.
4. Check camshaft bearingsforoverheating, wear
and scoring andthatlubrication holesare
clear, replace asnecessary. Bearingsmustbe
replaced asaset.
5. Check camfollower slides,rollersandcam
follower guidesforsigns ofwear.
6. Check thateach slidemoves freelyinits guide
and thatoilways areclear. Camfollowers must
be replaced asan assembly.
7. Check thatoilpassage inoil jet tube isclear.
8. Insert apiece ofstiff wire inend ofoil jet tube
and check thatnon-return valvecanbe
depressed andcloses underspring pressure.  
						

							ENGINEOVERHAUL 75
Camshaft
-refit andcheck end-float
1. Remove alltraces ofgasket frombaffle plate
and cylinder blockusing suitable gasket
removal sprayandaplastic scraper.
2. Lubricate cams,journals andbearings with
engine oil.
3. Ensure thrustplateboltholes incylinder block
are clean anddry.
4.Carefully insertcamshaft intocylinder block
taking carenottodrop endofcamshaft onto
bearings.
5. Fitanew thrust plate,fitbolts andtighten to9
Nm.
6. Temporarily fitcamshaft timinggear,fitand
tighten boltsufficiently topull gear fullyonto
camshaft.
7. Attach amagnetic baseDTItofront ofcylinder
block withstylus ofgauge contacting machined
face ofgear adjacent togear teeth.
8. Push camshaft fullyrearwards andzero gauge.
9. Pull camshaft fullyforwards andcheck that
end-float isbetween 0.1and 1.2mm.
10. Ifend-float exceeds0.2mm with new thrust
plate fitted, camshaft mustbereplaced.
11. Remove DTIand timing gear.
12. Fitoiljet tube andtighten to17 Nm.
13. Lubricate components ofeach camfollower
with engine oil.
14. Lubricate camfollower boreswithengine oil.    
						

							ENGINE 76OVERHAUL
15.Insert eachcamfollower guideintoitsoriginal
location inthe cylinder block.
16. Fitnew retaining bolt,locate endofbolt incam
follower guide.
17. Tighten boltto14 Nm.
18. Fitroller ensuring thatreference markmade
during removal istowards frontofcylinder
block.
19. Fitcam follower slideensuring thatword
FRONT ormark Fistowards frontofcylinder
block.
20. Repeat aboveprocedures forremaining cam
follower assemblies.
21. Fitadry, new gasket tobaffle plate.
22. Fitbaffle plate,fit3bolts andfinger tighten in
their original locations.
23. Bolts aretightened whenfuelinjection pumpis
fitted. Cylinder
block-inspection
1. Thoroughly cleancylinder block,ensure allbolt
holes areclean anddry.
2. Remove alltraces ofcarbon fromcylinder head
gasket face.
3. Remove alltraces ofgaskets usingsuitable
gasket removal sprayandaplastic scraper.
4. Check allstuds fordamage, replaceas
necessary.
5. Check coreplugs forcorrosion andsigns of
leakage, replaceasnecessary.
6. Using aninternal micrometer, take2
measurements at90 °to each other attop of
bore. Thedifference betweenthe2
measurements isthe ovality ofthe bore.
Maximum ovality=0.127 mm
7. Repeat measurements 50mm from bottom of
each cylinder bore.
8. Measure fromsidetoside from below wear
ridge attop ofbore andabove wearridge at
bottom ofbore. Thedifference betweenthe2
measurements isthe taper.
Maximum taper=0.254 mm   
						

							ENGINEOVERHAUL 77
9.
Check cylinder boreoverall wear,measure at
several pointsfromsidetoside, thelargest
diameter recorded isthe 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: Donot de-glaze cylinderbores.
10. Cylinder boreswhich areworn inexcess of
0.177 mmover theabove boresizes mustbe
rebored andtheappropriate oversizepistons
and rings fitted.
CAUTION: Cylinderboresmustbehoned
to finished size.
11. Fitoilpick-up anddrain pipes andsump.
12. Fitcylinder head.
13. Fitflywheel/drive platehousing.
14. Fittiming beltrear cover andoilpump.
15. Fittiming belt.
16. Fitfuel injection pump.
17. Fitoilfilter head.
18. Fitfuel liftpump.
19. Fitbrake servovacuum pump.  
						

							ENGINE
DATA, TORQUE &TOOLS 1
ENGINE
DATA
Rocker shaft
Rocker shaftwear-maximum 0.025mm
..................
Rocker armshaft tobush clearance -maximum 0.12mm
....
Valve clearance -inlet andexhaust 0.20mm
..............
Oil pump
Outer rotortohousing clearance 0.025to0.075 mm
................
Inner toouter rotorclearance 0.025to0.075 mm
..................
Outer rotorend-float 0.026to0.135 mm
.........................
Relief valvespring freelength 68.0mm
..................
Cylinder head
Cylinder headmaximum warpage 0.08mm
...............
Maximum movement ofvalve toguide 0.15mm
...........
Valve stemdiameter:
Inlet 7.96mm
......................................
Exhaust 7.94mm
...................................
Valve headstand down:
Inlet 0.81to1.09 mm
......................................
Exhaust 0.86to1.14 mm
...................................
Valve seatinsert faceangle:
Inlet 60°
......................................
Exhaust 45°
...................................
Valve faceangle:
Inlet 60°00 to60 °30
......................................
Exhaust 45°00 to45 °30
...................................
Valve spring freelength 46.28mm
.......................
Timing belttension ontorque wrench
Used belt 12Nm
..................................
New belt 15Nm
...................................
Drive plate-automatic gearbox
Setting height 12.4mm
...............................