Land Rover 300tdi Diesel Engine Overhaul 1997 Rover Manual

							ENGINEOVERHAUL 49
Inspecting
components
1. Check clutchfaceofflywheel forscoring or
signs ofoverheating (blueing ),ifdeep scoring
or signs ofoverheating exist,flywheel mustbe
replaced.
2. Check teethofstarter ringgear forchipping
and wear, replace ringgear asnecessary. Starter
ringgear -replace
1. Drill a3m m diameter holetothe depth ofthe
ring gear atthe root of2teeth.
CAUTION: Ensuredrilldoes notcontact
flywheel.
2. Using acold chisel, splitringgear.
WARNING: Wearsuitable eyeprotection
and cover flywheel withcloth toprotect
against flyingfragments.
3. Remove ringgear fromflywheel.
4. Heat replacement ringgear uniformly to250
° C.   
						

							ENGINE 50OVERHAUL
5.Position ringgear toflywheel withsquare edge
of teeth towards flywheel flange.
6. Press ringgear ontoflywheel, allowtoair cool. Flywheel
-refit
1. Ensure boltholes incrankshaft areclean and
dry.
2. Ensure 2slave 8m m bolts arescrewed fully
into flywheel.
3. Using assistance, positionflywheel on
crankshaft.
NOTE: Dowellocated.
4. Fitand finger tighten 8bolts.
5. Restrain crankshaft usingtoolLRT-12-080
and tighten flywheel boltsbydiagonal selection
to 146 Nm.
6. Remove toolLRT-12-080 andcrankshaft
pulley.
7. Remove slaveboltsfromflywheel.  
						

							ENGINEOVERHAUL 51
DRIVE
PLATE
Remove
1. Temporarily fitcrankshaft pulley-if removed.
2. Position toolLRT-12-080 tocrankshaft pulley,
secure using4bolts.
3. Restrain crankshaft usingtoolLRT-12-080
and remove 8bolts securing driveplate,
discard lockingplate-if fitted.
4. Remove driveplate, recover spacerandshims.
NOTE: Dowellocated.    
						

							ENGINE 52OVERHAUL
Inspecting
components
1. Check starterringgear teeth forchipping or
wear, replace ringgear ifnecessary.
2. Check driveplateforvisible signsofdamage
or distortion, replacedriveplateifnecessary. Drive
plate-refit
1. Check thatboltholes incrankshaft areclean
and dry.
2.Position spacer,lessoriginal shimsto
crankshaft.
3. Position astraight edgeacross spacer.
4. Measure andrecord distance between gearbox
mating flangeofdrive platehousing and
straight edge.
5. Repeat procedure onopposite sideofspacer.
6. Add the2measurements obtainedtogether
and calculate theaverage.
7. Calculate thedifference betweentheaverage
figure obtained and12.4 mm.
8. Select shimsfromtherange available which
equal thefinal figure obtained.
NOTE: Shimsareavailable risingin
increments of0.1 mm from 1.0mm to2.1
mm inthickness.  
						

							ENGINEOVERHAUL 53
9.Position selected shims,spacer anddrive plate
to crankshaft.
NOTE: Dowellocated.
10. Fitand finger tighten 8bolts.
NOTE: Locking plateisno longer required.
11. Restrain crankshaft usingtoolLRT-12-080
and tighten driveplateboltsto146 Nm.
12. Remove toolLRT-12-080 andcrankshaft
pulley. FLYWHEEL/DRIVE
PLATEHOUSING
Remove 1. Remove flywheel/drive plate.
NOTE:Flywheel housingillustrated.
2. Remove 2bolts securing topofhousing to
cylinder block.
3. Remove 4bolts securing housingtoengine
mountings.
4. Progressively slackenthenremove 6bolts
securing housingtocylinder block.
5. Remove housing.    
						

							ENGINE 54OVERHAUL
Refit
1. Remove alltraces ofsealant frommating faces
of housing andcylinder blockusing solvent
from kitGUG 705548GM.
2.Apply abead ofsealant fromkittocylinder
block.
3. Position housingtocylinder block.
4. Fitand finger tighten bolts.
5.Using sequence shown,tightenboltsto45 Nm.
NOTE: Ifengine mounting boltswerenot
fitted, omitbolts 8,10, 11and 12from
tightening sequenceandre-number
accordingly.
6. Fitflywheel/drive plate.   
						

							ENGINEOVERHAUL 55
CRANKSHAFT,
CAMSHAFT,PISTONSAND
CYLINDER BLOCK
1. Remove timingbeltrear cover.
2. Remove flywheel/drive platehousing.
3. Remove fuelliftpump.
4. Remove cylinderhead.
5. Remove sump,oilpick-up anddrain pipes.
6. Remove oilfilter head.
7. Remove brakeservovacuum pump. Crankshaft
rearoilseal -remove
1. Remove 5bolts securing rearoilseal housing
to cylinder block.
2. Remove anddiscard oilseal andhousing.
3.
Early engines:Remove anddiscard Oring.
4. Remove anddiscard gasket.   
						

							ENGINE 56OVERHAUL
Big-end
bearings -remove
1. Suitably identifyeachoiljet tube toits fitted
location.
2. Remove boltsecuring eachoiljet tube
assembly tocylinder block.
3. Remove oiljet tube assemblies.
NOTE: Dowellocated.
4. Recover sealingwashers.
CAUTION: Oiljettube bolts incorporate a
non-return valve.
5. Temporarily fitcrankshaft pulleybolt.
6. Suitably identifyfittedposition ofeach big-end
bearing captoits connecting rodand each
connecting rodtoits respective cylinderbore.
7.Rotate crankshaft tobring numbers 1and 4
connecting rodstoBDC.
8. Remove anddiscard 2nuts securing each
big-end bearingcap.
9. Remove numbers 1and 4big-end bearing
caps, recover bearingshells.
10. Slide suitable piecesofplastic tubingover
each connecting rodbolt.
11. Push numbers 1and 4connecting rodsup
cylinder boresuntilthey areclear ofcrankshaft
journals.
12. Repeat aboveprocedures toremove numbers
2 and 3big-end bearings.
CAUTION: Big-endbearingshellsmust
always bereplaced.   
						

							ENGINEOVERHAUL 57
Crankshaft
andmain bearings -remove
1. Suitably identifyeachmainbearing capand its
fitted direction incrankcase.
2. Starting atnumber 3main bearing capand
working outwards, progressively slacken,then
remove bearingcapbolts. Keepboltswiththeir
respective mainbearing caps.
3. Using thefingers only,rockeach mainbearing
cap until itis released fromitsretaining dowels.
CAUTION: Donot tapmain bearing caps
sideways torelease.
4. Remove anddiscard oilseals fromnumber 5
main bearing cap.
5. Recover lowermainbearing shellsfrom
bearing caps.
6. Using assistance, removecrankshaft. 7.
Recover groovedthrustwashers andupper
main bearing shells.
CAUTION: Mainbearing shellsandthrust
washers mustalways bereplaced.
8. Remove pistonsandconnecting rods.   
						

							ENGINE 58OVERHAUL
Crankshaft
-inspection
NOTE: Crankshafts maybereground 0.25
mm undersize onboth main andbig-end
journals.
See Crankshaft -regrinding.
1. Clean crankshaft andmain bearing caps,
ensure oilways areclear.
2. Check mainandbig-end journals forsigns of
scoring, excessive wearandoverheating.
3.Check mainandbig-end bearingjournals for
wear andovality, make3checks at120
° intervals incentre ofjournals.
Maximum ovality=0.040 mm
Main bearing journaldiameter =63.475 to
63.487 mm
Service limit=63.36 mm
Regrind diameter =63.225 to63.237 mm
Big-end bearingjournaldiameter =58.725 to
58.744 mm
Service limit=58.637 mm
Regrind diameter =58.475 to58.494 mm
4. Ifbearing journaldiameters areless than
service limit,crankshaft maybereground to
specified regrinddiameter and0.25 mm
oversize bearingshellsfitted.
5.Using amicrometer, measurediameterateach
end ofmain andbig-end bearingjournals.
6. From measurements obtained,calculatetaper
of each journal.
Maximum journaltaper-end toend =0.025
mm
7. Support eachendofcrankshaft inVee blocks.
8. Position aDTI with stylus contacting centre
main bearing journal.
9. Rotate crankshaft andcheck run-out doesnot
exceed 0.076mm.
CAUTION: Ifrun-out exceeds abovefigure,
renew crankshaft.