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300 TDi ENGINE OVERHAUL MANUAL

1. Oil pump Outer rotor to housing clearance Inner to outer rotor clearance Outer rotor end float Relief valve spring free length Cylinder head Cylinder head maximum warpage Maximum movement of valve to guide Valve stem diameter Inlet Exhaust Valve head stand down Inlet Exhaust Valve seat insert face angle Inlet Exhaust Valve face angle Inlet Exhaust Valve spring free length Timing belt tension on torque wrench Used belt New belt a APE It ieee hs eG ae Drive plate automatic gearbox Setting height ENGINE Bees 0 025 to 0 075 mm 0 025 to 0 075 mm 0 026 to 0 135 mm 68 0 mm 0 81 to 1 09 mm 0 86 to 1 14 mm 60 00 to 60230 45 00 to 45 30 46 28 mm DATA TORQUE amp TOOLS 1 ENGINE Crankshaft Maximum bearing journal ovality 0 040 mm Maximum bearing journal run out 0 076 mm Main bearing journal diameter 63 475 to 63 487 mm Service mt 63 36 mm Regrind diameter 63 225 to 63 237 mm Big end journal diameter 58 725 to 58 744 mm Service mt 58 637 mm Regrind 58 475 to 58 494 Main big end bearing oversizes available 0 25 mm Main bearing clearance 0 031 to 0 079 mm Crankshaft end float 0 05 to 0 15 mm Thrust washer oversizes available 18 OVEISIZE eee RETE 0 06
2. Position a DTI with stylus contacting centre main bearing journal Rotate crankshaft and check run out does not exceed 0 076 mm CAUTION If run out exceeds above figure renew crankshaft Crankshaft regrinding NOTE Crankshaft journals may be A reground to the following dimensions Main bearing journals 63 225 to 63 237 mm Big end bearing journals 58 475 to 58 494 mm CAUTION Rotation of crankshaft must be in an ANTI CLOCKWISE direction when viewed from flywheel end of crankshaft Co 12 2942 1 Grind journals ensuring that grinding wheel travels beyond edge of journal A to avoid formation of a step B CAUTION Take care not to damage fillet A radius C 2 Final finishing should be carried out using a static lapping stone with crankshaft rotating in a CLOCKWISE direction when viewed from flywheel end of crankshaft 3 On completion of grinding operations thoroughly clean crankshaft ensuring that all oil passages are clear ENGINE Bees Main bearing caps and saddles inspection 1 Ensure main bearing cap bolts and bolt holes are clean and dry 12M2943 Fit each main bearing cap less bearing shells to its correct location ensuring that direction marks on cap are facing the correct way Fit and tighten each pair of main bearing cap bolts to 133 Nm Slacken the bolt on one side of each main bearing cap Using feeler gauges check that there is no gap between e
3. Inspecting components 1 Check starter ring gear teeth for chipping or wear replace ring gear if necessary 2 Check drive plate for visible signs of damage or distortion replace drive plate if necessary 52 OVERHAUL Drive plate refit 1 Check that bolt holes in crankshaft are clean and dry 12M3684 4 1 Position spacer less original shims to crankshaft Position a straight edge across spacer Measure and record distance between gearbox mating flange of drive plate housing and straight edge Repeat procedure on opposite side of spacer Add the 2 measurements obtained together and calculate the average Calculate the difference between the average figure obtained and 12 4 mm Select shims from the range available which equal the final figure obtained NOTE Shims are available rising in increments of 0 1 mm from 1 0 mm to 2 1 mm in thickness ENGINE esssi FLYWHEEL DRIVE PLATE HOUSING Remove 1 Remove flywheel drive plate 12M3683 9 Position selected shims spacer and drive plate to crankshaft NOTE Dowel located 10 Fit and finger tighten 8 bolts A 11 Restrain crankshaft using tool LRT 12 080 and tighten drive plate bolts to 146 Nm 12M2890 NOTE Locking plate is no longer required i NOTE Flywheel housing illustrated 12 Remove tool LRT 12 080 and crankshaft 2 Remove 2 bolts securing top of housing to pulley cylinder b
4. Rocker cover flange nuts Sealing washer Oil filler cap Rocker cover Rocker cover gasket Rocker shaft Rocker shaft pedestal Flange bolt Washer ENGINE Bees Rocker arm bush Adjusting screw Locknut Rocker arm Spacer Pedestal stud Nut Crankcase breather cyclone unit OT ring DESCRIPTION AND OPERATION 7 ENGINE 12M2835 DESCRIPTION AND OPERATION 8 CYLINDER HEAD Valve cap Collets Valve spring cup Valve spring Valve spring seat Valve stem seal Valve guide Exhaust valve seat Exhaust valve 10 Inlet valve seat 11 Inlet valve 12 Cylinder head bolt M12 long 13 Cylinder head bolt M12 short 14 Cylinder head bolt M10 OO JO Om P AM ch ENGINE Bees Heater hose adaptor Engine lifting brackets Core plugs Cylinder head gasket Thermostat housing gasket Coolant filler plug Thermostat housing Thermostat Coolant outlet elbow Coolant temperature sensor Sealing washer DESCRIPTION AND OPERATION 9 N 12 18 17 16 15 12 3635 ENGINE 10 DESCRIPTION AND OPERATION TIMING BELT REAR COVER AND GEARS Joo P GO MM Camshaft oil seal Gasket Crankshaft front oil seal Timing belt rear cover Injection pump drive gear Hub plate Nut injection pump hub Bolt injection pump hub plate Camshaft drive gear Washer camsh
5. pistons are half way up cylinder bores Position the selected cylinder head gasket on cylinder block ensuring that word TOP is facing upwards Using assistance fit cylinder head ensuring that it is located on dowels ENGINE Bees M12 140 M12 x 140 M12 140 M12 x 140 M12 x 140 M10 x 117 M10 x 117 M10 x 117 M10 x 117 M12 x 100 M12 x 100 M12 x 100 M12 x 100 M12 x 140 M12 x 140 M12 x 140 M12 x 140 M12 x 140 12M2916 7 Fit cylinder head bolts of the correct length in positions shown CAUTION Do not drop bolts into cylinder block 8 Tighten bolts until bolt heads just contact cylinder head 12M2917 9 Using sequence shown tighten cylinder head bolts to 40 Nm OVERHAUL 29 ENGINE 10 11 12 13 14 15 30 Assemble degree plate LRT 12 007 toa torque wrench or extension bar Make a suitable pointer from welding rod and attach it to the rocker shaft pedestal bolt hole adjacent to number 1 cylinder head bolt Using sequence shown tighten cylinder head bolts a further 60 NOTE Re position the pointer as necessary to enable degree of tightening to be measured Using sequence shown tighten each bolt a further 60 CAUTION Bolts must be tightened in sequence 60 at a time never 120 one operation Using sequence shown tighten bolts numbers 1 2 7 8 9 10 15 16 17 and 18 a further 20 Remove pointer OVERHAUL 16 17 18 1
6. Overhaul Manual Dieselmotor Revisiehandboek Moteur Diesel Manuel de r vision Dieselmotor berholungsanlitung Motore Diesel Manuale di revisione Motor Diesel Manual de revisi n Motor Diesel Manvol de revis o 300 TDi ENGINE OVERHAUL MANUAL This engine is fitted to the following Models from 1995 onwards Discovery Defender Range Rover Classic Publication Part No LRL 0070ENG Published by Rover Technical Communication 1997 Rover Group Limited LAND ROVER INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub section is given at the bottom each page This manual contains procedures for overhaul of the engine For all other information regarding adjustments removal of oil seals and engine consult the Repair Manual for the model concerned This manual is divided into 3 sections Description and Operation e Overhaul and Data Torque amp Tools To assist filing of revised information each sub section is numbered from page 1 Individual items are to be overhauled in the sequence in which they appear in this Manual Items numbered in the illustrations are referred to in the text Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool Where usage is not obvious the tool is shown in use Operations also include reference to wear limits relevant data torque figu
7. re check all clearances and adjust as necessary OVERHAUL 17 ENGINE CYLINDER HEAD Remove 1 Remove rocker shaft 2 Remove fuel injectors 3 Remove glow plugs 12M2897 4 Using sequence shown progressively slacken then remove and discard 18 bolts securing cylinder head 5 Using assistance remove cylinder head A 6 Remove cylinder head gasket NOTE Dowel located 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 18 OVERHAUL 12M2898 8 Remove 2 bolts securing coolant outlet elbow 9 Remove coolant outlet elbow 10 Remove thermostat from housing 12M2927 12 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 12M2899 14 14 Remove 2 bolts securing engine front lifting bracket remove bracket ENGINE Besos Valves and springs remove 1 Support cylinder head clear of valves use a hollow drift and tap each valve spring cap to free collets 2 Position cylinder head on its side LRT 12 034 12M2900 3 Using tool L
8. 13 Remove timing pin and flywheel drive plate locking tools 1 m 14 Fit plug to flywheel housing tighten to 12 Nm 19 Fita dry new gasket to timing belt rear cover 15 Remove crankshaft pulley bolt 20 Position timing belt front cover to rear cover 21 Fit bolts of the correct length in positions shown OVERHAUL 9 ENGINE 9 7 5 3 11 13 12M2861 22 Tighten bolts in sequence shown to 25 Nm 23 Lightly oil crankshaft spigot fit Woodruff key and crankshaft pulley 10 OVERHAUL 24 25 26 27 LRT 12 080 12M2862 Position tool LRT 12 080 to crankshaft pulley retain tool using 4 bolts Fit crankshaft pulley flange head bolt Restrain crankshaft and tighten bolt to 80 Nm then further 90 Remove tool LRT 12 080 ROCKER SHAFT Remove 12M2863 Disconnect breather hoses from crankcase breather cyclone unit Remove bolt securing cyclone unit to rocker cover Remove cyclone unit remove and discard O ring Disconnect breather hoses from cylinder block and rocker cover ENGINE Remove 3 flange nuts securing rocker cover recover sealing washers Remove rocker cover remove and discard gasket Slacken locknut on each tappet adjusting screw slacken adjusting screws until they are clear of push rods Working from the centre outwards progressively slacken then remove 3 nuts and 2 bolts securing rocker shaft pedestals to cylinder head CAUTION Inse
9. 21 22 23 12M2872 Lubricate a new O ring with engine oil and fit to crankcase breather cyclone unit Fit cyclone unit to rocker cover fit bolt and tighten to 9 Nm Connect breather hoses to cyclone unit rocker cover and cylinder block ENGINE Bees 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 1 9 SE lt gt las ra d pA 12M2870 2 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
10. Lubricate valve pads with engine oil and fit to their original positions Position rocker shaft to cylinder head fit but do not tighten 3 nuts Remove slave bolts from pedestals 1 and 5 fit but do not tighten 2 bolts 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 Working from the centre outwards progressively tighten 3 nuts and 2 bolts to 5 Nm 12 2869 Make a suitable pointer from welding rod and position it to number 1 pedestal stud Temporarily fit a nut to secure pointer to stud Assemble degree plate LRT 12 007 toa suitable torque wrench or extension bar Tighten the centre pedestal nut a further 50 Tighten 2 pedestal bolts and number 5 pedestal nut a further 50 Remove pointer and secure it to number 5 pedestal stud Tighten number 1 pedestal nut a further 50 Remove pointer Adjust valve clearances Thoroughly clean mating faces of rocker cover and cylinder head remove all traces of gasket material using gasket removal spray and a plastic scraper LRT 12 007 ENGINE Bees OVERHAUL 15 ENGINE 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 16 flange nuts and working from centre outwards tighten to 10 Nm OVERHAUL
11. Remove 4 bolts securing filter head to cylinder block 3 Remove filter head remove and discard 36 gasket OVERHAUL Thermostatic valve remove 12M2894 2 Secure oil filter head in a soft jawed vice with thermostatic valve vertically upwards Remove 2 bolts securing thermostatic valve extension housing to oil filter head Remove extension housing remove and discard O ring Withdraw thermostatic valve and spring CAUTION Do not separate valve from spring Inspecting components 1 Check thermostatic valve spring for distortion and corrosion CAUTION Do not separate valve from AN spring 2 Check valve for corrosion seating faces of valve and extension housing for damage and pitting replace valve as an assembly 3 Check valve bore for corrosion Light corrosion must be removed from valve bore using grade 600 emery cloth soaked in oil 4 Check oil passages in oil filter head are clear ENGINE Bees Thermostatic valve refit 1 Secure oil filter head in a soft jawed vice with thermostatic valve bore vertically upwards 12M2895 0 Lubricate a new O ring with engine oil and fit to thermostatic valve extension housing Lubricate thermostatic valve and bore with engine oil Fit thermostatic valve and spring Position extension housing to oil filter head ensuring that thermostatic valve is positioned centrally in housing Fit and progressively
12. as necessary 12M2969 Using an internal micrometer take 2 measurements at 90 to each other at top of bore The difference between the 2 measurements is the ovality of the bore Maximum ovality 0 127 mm Repeat measurements 50 mm from bottom of each cylinder bore Measure from side to side from below wear ridge at top of bore and above wear ridge at bottom of bore The difference between the 2 measurements is the taper Maximum taper 0 254 mm ENGINE 9 Check cylinder bore overall wear measure at several points from side to side the largest diameter recorded is the 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 Do not de glaze cylinder bores 10 Cylinder bores which are worn in excess of 0 177 mm over the above bore sizes must be rebored and the appropriate oversize pistons and rings fitted CAUTION Cylinder bores must be honed to finished size 11 Fit oil pick up and drain pipes and sump 12 Fit cylinder head 13 Fit flywheel drive plate housing 14 Fit timing belt rear cover and oil pump 15 Fit timing belt 16 Fit fuel injection pump 17 Fit oil filter head 18 Fit fuel lift pump 19 Fit brake servo vacuum pump OVERHAUL 77 ENGINE DATA Rocker shaft Rocker shaft wear maximum Rocker arm shaft to bush clearance maximum Valve clearance inlet and exhaust
13. for any piston exceeds figure given cylinder block must be rebored OVERHAUL 12 2960 Measure gudgeon pin diameter at each end and centre of pin Diameter 30 156 to 30 162 mm Renew gudgeon pin and piston as an assembly if diameter is less than specified or if excessive pin to piston clearance is evident Check small end bushes for signs of wear or overheating check that gudgeon pins are a tight sliding fit in the bushes with no perceptible side play CAUTION Small end bushes cannot be replaced a new connecting rod must be fitted Using the fingers only check that a new big end bearing cap nut runs freely on each connecting rod bolt if any nut is tight on the threads renew both bolts on that connecting rod CAUTION Retain nuts with their A respective connecting rod bolts 10 Check connecting rods for alignment maximum 0 127 mm per 25 4 mm of length Replace any rod which is misaligned 11 12 13 14 A 12M2961 Assemble each big end bearing cap less bearing shells to its respective connecting rod Fit and tighten big end bearing cap nuts to 59 Nm Slacken the nut on one side of connecting rod Using feeler gauges check that there is no gap between bearing cap and connecting rod on the side of the cap with the slackened nut CAUTION If clearance exists connecting rod must be replaced 15 Remove nuts and big end bearing caps CAUTION Retain nuts and b
14. numbers 2 and 3 pistons and connecting rods 72 OVERHAUL Oil jet tubes refit 12M2972 Position sealing washers in cylinder block Fit oil jet tubes to their original locations Fit banjo bolts and washers tighten bolts to 17 Nm ENGINE Bees Camshaft remove 12M2950 Remove oil jet tube Clean area around baffle plate Note fitted position of 3 bolts securing baffle plate On 12M2951 4 Remove 3 bolts securing baffle plate to cylinder block remove plate 5 Remove and discard gasket 12M2952 CAUTION Do not remove cam follower guide retaining bolts until slides and rollers have been removed keep components of each cam follower assembly in their fitted order 6 Using long nosed pliers remove cam follower slide Remove roller and suitably identify which side of roller faces towards front of cylinder block Remove and discard bolt retaining cam follower guide Remove cam follower guide Repeat above procedures for remaining cam follower assemblies OVERHAUL 73 ENGINE Camshaft bearings and cam followers inspection 1 Check camshaft cams and bearing journals for overheating wear and scoring replace camshaft if necessary 2 If camshaft is replaced new bearings must be fitted 3 Check timing gear drive pin for security 4 Check camshaft bearings for overheating wear and scoring and that lubrication holes are clear replace a
15. pitting if light pitting cannot be removed during valve grinding operations valves may be refaced CAUTION If refacing results in valve head stand down being exceeded valves must be replaced 60 450 12M2911A 4 Check valve seating face angles Inlet 60 00 to 60 30 included angle 2120 Exhaust 45 00 to 45 30 included angle 90 5 Reface or replace valves as necessary 6 Check each valve stem for wear measure at each end and centre of valve stem Inlet 7 96 mm Exhaust 7 94 mm 7 Replace any valve with stems that are worn OVERHAUL 21 ENGINE 22 Insert a new valve into each guide in turn and with head of valve positioned 8 0 mm above seat insert measure side to side movement of valve head using a suitable DTI Maximum valve head movement 0 15 mm Replace any valve guide which permits valve head movement in excess of the above figure OVERHAUL Valve guides renew LRT 12 036 wo 12 2904 Cy 2 Support cylinder head combustion face upwards on blocks of wood Using tool LRT 12 036 drift valve guide out of cylinder head discard guide Clean valve guide bore Heat cylinder head uniformily to 120 C WARNING Take care when handling heated cylinder head 12 2905 Position cylinder head on bed of hand press Position replacement valve guide to cylinder head ensuring that groove for valve stem seal is facing away from cy
16. respective connecting rods and caps 14 Remove all traces of Plastigage using an oily rag 15 Repeat above procedures for numbers 2 and 3 big end bearings ENGINE Bees Crankshaft main and big end bearings refit Crankshaft and main bearings CAUTION Cylinder bores must be inspected before crankshaft is refitted See cylinder block inspection 1 Lubricate selected main bearing shells thrust washers and crankshaft journals with engine oil ensure bolt holes in bearing saddles are clean and dry fit bearing shells in main bearing caps and saddles 6 LRT 12 035 12M2947 2 Fit seal guides LRT 12 035 to cylinder block ensuring that edges of guides are parallel to edge of main bearing cap recess 3 Using a sharp blade cut a 0 40 to 0 80 mm wide chamfer on edge of new seals 4 Lubricate oil seals with engine oil and fit to number 5 main bearing cap 5 Fit selected thrust washers to centre main bearing saddle NOTE Grooved side of thrust washers A must face outwards 6 Using assistance fit crankshaft 7 Fit main bearing caps and bolts ensuring that they are in their fitted order and direction marks are facing the correct way Lightly lubricate main bearing cap bolts fit and finger tighten bolts OVERHAUL 63 10 11 12 13 64 Tighten centre main bearing cap bolts to 133 Nm Temporarily fit crankshaft pulley bolt and check that crankshaft rotates freely and smoothly Ti
17. rockers operating 2 valves per cylinder via camshaft followers and push rods from a single camshaft supported in the cylinder block by 4 bearings and driven by a gear and toothed belt from the crankshaft A lobe formed between the 2 inner bearing journals provides drive for the fuel lift pump and another lobe between the 2 drive end journals provides drive for the brake servo pump Camshaft end float is controlled by a thrust plate bolted to the cylinder block Graphite coated aluminium alloy pistons are fitted with 2 compression and an oil control ring and are secured to the connecting rods by semi floating gudgeon pins which are an interference fit in the small end bush A swirl chamber is incorporated in the piston crown to facilitate combustion The timing case consists of cast aluminium alloy front and rear covers which house the oil pump crankshaft and camshaft front oil seals and which also carry the fuel injection pump and drive belt idler pulley Housed within the timing case housing is the crankshaft gear which provides drive for the camshaft and fuel injection pump gears via a rubber toothed belt ENGINE Bees DESCRIPTION AND OPERATION 15 ENGINE 12 7 8 7 8 7 8 7 8 7 Lubrication The engine lubrication system is of the wet sump type oil pressure being provided by the rotor type oil pump 1 driven directly by the crankshaft Oil is drawn from the sump 2 through the strainer 3 suction pipe 4 and pas
18. 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 46 OVERHAUL ENGINE Bees FLYWHEEL AND STARTER RING GEAR Sump refit 1 Clean sump and remove all traces of sealant using solvent from kit GUG 705548GM Flywheel remove 2 Apply a2 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 1 Screw 2 slave 8 mm bolts into flywheel 12M2922 20 22 18 4 Fit 22 sump bolts and tighten in sequence shown to 25 Nm 5 Check that sump drain plug is tightened to 35 Nm OVERHAUL 4 7 ENGINE LRT 12 080 12M2885 12M2884 4 Restrain crankshaft pulley using tool LRT 12 080 and remove 8 bolts securing flywheel discard locking plate if fitted 5 Using assistance remove flywheel using 2 2 Temporarily fit crankshaft pulley slave bolts 3 Position tool LRT 12 080 to crankshaft pulley secure with 4 bolts NOTE Dowel located A 48 OVERHAUL Inspecting components 1 Check clutch face of flywheel for scoring or signs of overheating blueing if deep scoring or signs of overheating exist flywheel must be replaced 2 Check teeth of starter ring gear for chipping and wear replace ring gear as necessary ENGINE Bees Starter ring gear replace
19. 0 Nm 20 Nm 25 Nm 80 Nm 25 Nm 25 Nm 25 Nm 25 Nm 9 Nm 17 Nm 17 Nm 14 Nm 59 Nm 133 Nm DATA TORQUE amp TOOLS 3 ENGINE TOOL NUMBERS LRT 12 007 LRT 12 031 LRT 12 035 LRT 12 038 LRT 12 044 LRT 12 045 LRT 12 046 LRT 12 049 LRT 12 077 LRT 12 078 LRT 12 079 LRT 12 080 LRT 12 082 LRT 12 501 LRT 12 502 LRT 12 515 MS 621 MS 627 4 DATA TORQUE amp TOOLS Degree plate Remover crankshaft camshaft gear Seal guide Remover valve guide Timing pin Fuel injection pump timing pin Replacer valve guide Remover crankshaft pulley Replacer oil seal Gear remover Replacer oil seal Retainer crankshaft pulley Replacer oil seal Handle set Pilot valve seat cutter Distance piece 45 cutter 60 cutter
20. 3 2ndoversize 0 127 Big end bearing 0 025 to 0 075 mm Connecting rod end float 0 15 to 0 35 mm Camshaft End float 12r oret ee sexe E he del ane 0 1 to 0 2 mm Pistons and connecting rods Piston diameter Standard 2 2 ene ere 90 395 mm istoversize es 90 649 mm 2ndoversize 90 903 mm Piston to cylinder bore clearance 0 075 mm Connecting rod misalignment maximum 0 075 mm per 25 4 mm Piston rings Fitted gap in cylinder bore Top compression 0 40 to 0 65 mm 2nd compression 0 30 to 0 50 mm Oil control 0 30 to 0 60 mm Ring to groove clearance Top compression 0 167 to 0 232 mm 2nd compression 0 05 to 0 08 mm Oil control ring assembly 0 05 to 0 08 mm Cylinder block Cylinder bore maximum ovality 0 127 mm Cylinder bore maximum taper 0 254 mm Cylinder bore maximum wear 0 177 mm Cylinder bore size Standard sosie rinia eon nee Se wee 90 47 mm For 1st oversize piston 90 73 mm For 2nd oversize piston 90 98 mm 2 DATA TORQUE amp TOOLS TORQUE FIGURES Timing belt ten
21. 4 Remove all traces of grinding paste on 12M2914 completion 5 Check valve head stand down of each valve Insert each valve into its respective guide 2 Using a straight edge and feeler gauges check and record stand down of each valve head 3 Compare figures obtained with those given below If any valve head has a stand down outside that specified valve and or seat insert must be replaced Valve head stand down Inlet valve A 0 81 to 1 09 mm Exhaust valve B 0 86 to 1 14 mm 26 OVERHAUL Valves and springs refit 1 Lubricate valve stems guides spring seats valve springs spring cups and collets with engine oil Lubricate new valve stem oil seals with engine oil and fit to valve guides Fit spring seat insert valve into its respective guide fit valve spring and spring cup Compress valve spring using tool LRT 12 034 and fit collets Remove tool LRT 12 034 Tap spring cup with a soft mallet to ensure that collets are correctly seated Repeat above procedures for remaining valves ENGINE esssi Cylinder head gasket selection CAUTION New cylinder head gasket should be same thickness as the original If however cylinder head pistons or crankshaft have been replaced it will be necessary to check piston stand proud in order to determine the correct thickness of gasket 1 Position a magnetic base DTI to cylinder block top face adjacent to number 1 cylind
22. 4 Tighten bolts progressively by diagonal selection to 25 Nm SUMP OIL PICK UP AND DRAIN PIPES Sump remove 12M2919 1 Using sequence shown progressively slacken then remove 22 bolts securing sump to cylinder block 2 Remove sump ENGINE Bees Cil pick up and drain pipes remove AR 1 e d X TAN 6 off i A i 12M2920 Remove bolt securing oil pick up pipe flange to timing belt rear cover Remove 4 bolts securing oil pick up and drain pipes to cylinder block and main bearing cap bolts Remove oil pick up and drain pipes Remove and discard O ring and gasket OVERHAUL 45 ENGINE 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 12M2921 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
23. 9 20 21 Fit glow plugs 23 12M2928 Position a new thermostat housing gasket to cylinder head Fit thermostat housing fit bolts and tighten to 25 Nm Position thermostat in housing Fit coolant outlet elbow fit bolts and tighten to 25 Nm Position engine front lifting bracket to cylinder head fit 2 bolts and tighten to 25 Nm Fit fuel injectors Fit rocker shaft assembly TIMING BELT REAR COVER AND OIL PUMP Timing belt rear cover remove 1 Remove timing belt tensioner and gears 2 Remove fuel injection pump 3 Remove sump and oil pick up pipe 5 1 7 10 4 8 12M2873 3 9 6 2 4 Using sequence shown progressively slacken then remove bolts securing timing belt rear cover remove cover 5 Remove and discard gasket 6 Remove and discard camshaft and crankshaft front oil seals ENGINE Bees Oil pump and oil pressure relief valve remove Oil pump Make suitable alignment marks between oil pump and timing belt rear cover Progressively slacken then remove 7 screws securing oil pump cover Remove oil pump cover Make suitable alignment marks between oil pump inner and outer rotors and outer rotor and timing belt rear cover OVERHAUL 31 ENGINE Oil pressure relief valve Inspecting components 12M2875 1 Check rotor clearances 1 Remove plug retaining oil pressure relief valve A Outer rotor to housing 0 025 to 0 075 mm 2 Withdraw spring and plung
24. NE Timing belt tensioner and gears refit 12M2850 Smear a new O ring with engine oil and fit to crankshaft Fit Woodruff key in slot in crankshaft Fit crankshaft gear on to crankshaft and using a soft mallet tap gear fully home 12 2851 4 Position camshaft timing gear and hub plate to camshaft fit bolt and washer finger tighten bolt Do not tighten bolt at this stage NOTE Later engines are fitted with a flange head bolt OVERHAUL 7 LRT 12 045 2 MAMANS UC 6 5 een 12 2852 Position fuel injection pump gear and hub plate to fuel injection pump hub ensuring that cut out in hub plate is aligned with timing pin hole in pump hub Fit 3 bolts position slots in gear mid way under bolt heads lightly tighten bolts CAUTION Do not fit bolts through elongated slots in hub plate Ensure gear does not move as bolts are tightened Insert timing pin LRT 12 045 in hub plate and injection pump hub If timing pin cannot be inserted slacken bolts and rotate gear until pin can be fitted lightly tighten bolts 8 Position flanged spacer on idler pulley stud 9 Fit timing belt tensioner pulley and bracket ensuring that hole in tensioner bracket is located on flanged spacer 10 Fit slotted washer with the slot vertical and fit bolt finger tight 11 Temporarily fit crankshaft pulley bolt to crankshaft LRT 12 044 12M2854 i NOTE Flywhee
25. RT 12 034 compress valve spring 4 Remove 2 collets from valve stem 5 Remove tool LRT 12 034 OVERHAUL 19 ENGINE COON 20 12M2901 Remove spring valve spring and spring seat Keep components in their fitted order Remove and discard valve stem oil seal Remove valve and retain in fitted order Repeat above procedures for remaining valves OVERHAUL Cylinder head inspection 1 Decarbonise cylinder head 2 Examine cylinder head for cracks pay particular attention to area between inlet and exhaust valve seats Cracks indicate engine has overheated and cylinder head must be replaced 3 Check core plugs for signs of corrosion and leakage replace as necessary 12M2902 4 Check cylinder head for warping using a straight edge and feeler gauges Maximum warping 0 08 mm CAUTION Cylinder head must not be N refaced if warping exceeds figure given head must be replaced 5 Check valve seat inserts for burning pitting or damage replace inserts if pitting cannot be removed by valve lapping in or refacing ENGINE Bees Valve springs inspection Valves and guides inspection 1 Remove carbon from valves 1 Check free length of each spring 2 46 28 mm 2 Examine head of each valve for cracks and 2 Check that end coils of each spring are square burning and valve seat for pitting or burning to body of spring replace valves as necessary 3 Check valve seating faces for
26. ach main bearing cap and saddle on the side of the cap with the slackened bolt lf a gap exists replace main bearing cap and re check If gap still exists cylinder block must be replaced CAUTION Do not attempt to machine main bearing caps or saddles 8 Remove main bearing caps CAUTION Keep main bearing cap bolts with their respective caps OVERHAUL 59 ENGINE Main bearing clearance checking CAUTION If crankshaft has been reground oversize main bearing shells must be fitted 1 Degrease new main bearing shells and ensure all traces of oil are removed from crankshaft journals 2 Fit new main bearing shells to saddles and main bearing caps ensuring that tags are located in recesses in saddles and bearing caps NOTE Number 5 main bearing shells are wider than numbers 1 to 4 12 2944 e 3 Using assistance fit crankshaft 4 Place a piece of Plastigage across width of each main journal 5 Fit main bearing caps to their correct location ensuring that direction marks are facing the correct way fit each pair of main bearing cap bolts and tighten to 133 Nm CAUTION Do not rotate crankshaft A 6 Remove main bearing caps and bearing shells CAUTION Retain main bearing shells and cap bolts with their respective main bearing caps 7 Measure widest portion of Plastigage on each main bearing journal using the scale supplied the graduation that corresponds to the widest portio
27. aft drive gear ENGINE 99 Bolt camshaft drive gear Idler pulley Retaining nut Crankshaft gear Bolt timing belt tensioner pulley Spacer timing belt tensioner pulley bolt Timing belt tensioner pulley and tensioner bracket Flanged spacer idler pulley O ring DESCRIPTION AND OPERATION 11 ENGINE 12M2837 8 6 7 9 10 12 DESCRIPTION AND OPERATION TIMING BELT AND FRONT COVER OD P OM ch Timing belt Gasket Access plate Bolt access plate Timing belt front cover SOON Oo ENGINE Bees Bolts timing belt front cover Wading plug Oil seal Crankshaft pulley Pulley bolt DESCRIPTION AND OPERATION 13 ENGINE Ww aa Q 12M2833 14 DESCRIPTION AND OPERATION OPERATION The 300 TDi is a 4 cylinder water cooled turbocharged diesel engine with a capacity of 2 5 litres The cast iron cylinder block is integral with the crankcase and incorporates direct bored cylinders The crankshaft is carried in 5 main bearings end float being controlled by thrust washers which are positioned on both sides of the centre main bearing The flywheel drive plate housing is an aluminium alloy casting secured to the rear of the cylinder block it also forms the mounting for the starter motor A plugged aperture in the housing allows access for the insertion of the timing pin The aluminium alloy cylinder head carries a conventional rocker shaft and
28. crankshaft pulley bolt to crankshaft amp 10 12M2842 Manual gearbox 10 Remove plug from bottom of flywheel housing 11 Rotate crankshaft clockwise using crankshaft pulley bolt until tool LRT 12 044 can be located in slot in flywheel CAUTION Do not rotate crankshaft anti clockwise and do not use camshaft or fuel injection pump gear bolts to rotate crankshaft 2 OVERHAUL o7 LRT 12 044 22 12 2880 Automatic gearbox 12 Rotate crankshaft clockwise using crankshaft pulley bolt until tool LRT 12 044 can be inserted through hole in engine plate and into slot in drive plate CAUTION Do not rotate crankshaft anti clockwise and do not use camshaft or fuel injection pump gear bolts to rotate crankshaft Ge Ses 12M2843 14 All engines 13 Check that timing mark on camshaft pulley is aligned with mark on timing belt rear cover and the crankshaft Woodruff key is aligned with the arrow cast on the rear cover 14 Remove crankshaft pulley bolt 15 Insert timing pin LRT 12 045 into fuel injection pump gear hub plate and injection pump hub 12M2844 16 Slacken but do not remove centre bolt securing camshaft drive gear to camshaft 17 If timing belt is to be refitted mark direction of rotation on outside surface of belt with chalk or similar soft material 18 19 20 21 ENGINE Bees 12M2845 Slacken but do not rem
29. ction pump OVERHAUL 39 ENGINE 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 O LRT 12 045 E ENEE 12M2938 Bug epe X 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 pin LRT 12 045 in hub plate and injection pump hub 10 Fit and tension timing belt 40 OVERHAUL FUEL LIFT PUMP Remove 12M2931 1 Disconnect fuel delivery pipe from fuel lift pump discard sealing washers CAUTION Plug open connections to prevent ingress of dirt ENGINE Bees 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 posi
30. d 1 Drill a 3 mm diameter hole to the depth of the ring gear at the root of 2 teeth CAUTION Ensure drill does not contact N flywheel 2 Using a cold chisel split ring gear WARNING Wear suitable eye protection and cover flywheel with cloth to protect against flying fragments 3 Remove ring gear from flywheel 4 Heat replacement ring gear uniformly to 250 C OVERHAUL 49 ENGINE Flywheel refit 1 Ensure bolt holes in crankshaft are clean and dry 2 Ensure 2 slave 8 mm bolts are screwed fully into flywheel 3 Using assistance position flywheel on crankshaft NOTE Dowel located Fit and finger tighten 8 bolts Restrain crankshaft using tool LRT 12 080 and tighten flywheel bolts by diagonal selection to 146 Nm 6 Remove tool LRT 12 080 and crankshaft pulley 7 Remove slave bolts from flywheel A 12M2887 5 Position ring gear to flywheel with square edge of teeth towards flywheel flange 6 Press ring gear on to flywheel allow to air cool 50 OVERHAUL ENGINE Bees DRIVE PLATE Remove LRT 12 080 12M2889 3 Restrain crankshaft using tool LRT 12 080 12 2888 and remove 8 bolts securing drive plate discard locking plate if fitted 4 Remove drive plate recover spacer and shims 2 Position tool LRT 12 080 to crankshaft pulley secure using 4 bolts 1 Temporarily fit crankshaft pulley if removed NOTE Dowel located OVERHAUL 51 ENGINE
31. earing caps with their respective connecting rod 16 Repeat above procedures for remaining connecting rods 17 18 19 ENGINE Besos Lubricate gudgeon pins and small end bushes with engine oil Assemble each connecting rod and gudgeon pin to its respective piston ensuring that bearing tag recess on connecting rod is on correct side of piston Fit new circlips to retain gudgeon pins ensuring they are correctly seated in their grooves OVERHAUL 69 ENGINE Piston rings checking CAUTION Prior to checking piston ring gaps in cylinder bores bores must be inspected measured and if reboring has been carried out the appropriate oversize pistons and rings used lt 5 1 ak pCO Tm Check fitted gap of each new piston ring in turn with ring positioned half way down cylinder bore Fitted gap of rings in bores Top compression 0 40 to 0 65 mm 2nd compression 0 30 to 0 50 mm Oil control rails 0 30 to 0 60 mm CAUTION Ensure that piston rings are suitably identified with the cylinder bore in which they were checked and that they are fitted to the piston for that cylinder bore 70 OVERHAUL 12M2964 Fit oil control rails and spring to piston Fit 2nd narrow compression ring with TOP marking uppermost Fit top compression ring with TOP marking uppermost Check that rings are free to rotate in their grooves ENGINE Bees Cil jet tubes inspec
32. en in this Manual must be used Locking devices where specified must be fitted If the efficiency of a locking device is impaired during removal it must be renewed The terms of the vehicle Warranty may be invalidated by the fitting of other than Land Rover recommended parts All Land Rover recommended parts have the full backing of the vehicle Warranty Land Rover Dealers are obliged to supply only Land Rover recommended parts 2 INTRODUCTION SPECIFICATION Land Rover are constantly seeking to improve the specification design and production of their vehicles and alterations take place accordingly While every effort has been made to ensure the accuracy of this Manual it should not be regarded as an infallible guide to current specifications of any particular component or vehicle This Manual does not constitute an offer for sale of any particular component or vehicle Land Rover Dealers are not agents of the Company and have no authority to bind the manufacturer by any expressed or implied undertaking or representation ENGINE Bees This page is intentionally left blank DESCRIPTION AND OPERATION 1 ENGINE 12M3637A 2 DESCRIPTION AND OPERATION CYLINDER BLOCK PISTONS AND CAMSHAFT Top compression ring 2nd compression ring Oil control ring Piston Gudgeon pin circlips Gudgeon pin Connecting rod Brake servo vacuum pump gasket Core plug Connecting r
33. er B Inner rotor to outer rotor 0 025 to 0 075 mm C Rotor end float 0 026 to 0 135 mm Remove inner and outer rotors Check rotors for damage wear and scoring Check oil pump cover for wear and scoring Check oil pressure relief valve spring free length is 68 0 mm Check plunger and relief valve bore for wear and scoring 7 Clean all traces of sealant from oil pump cover using solvent from kit GUG 705548GM 8 Remove all traces of sealant from relief valve plug threads in oil pump body eo BON CAUTION Do not use tap A 32 OVERHAUL Oil pump and oil pressure relief valve refit Oil pump 1 Thoroughly clean timing belt rear cover remove all traces of gasket using suitable gasket removal spray and a plastic scraper Remove all traces of sealant using solvent from kit GUG 705548GM Ensure oil pump cover screw holes are clean and dry Clean oil pump rotors and recess lubricate rotors and recess with engine oil CAUTION Ensure alignment marks made during dismantling are not erased Position inner and outer rotors in housing ensuring that reference marks are aligned Apply bead of sealant from kit to outer edge of oil pump cover fit cover to housing ensuring that reference marks are aligned Fit oil pump cover fit and progressively tighten 7 screws Check that pump rotates freely ENGINE Bees Oil pressure relief valve 1 Thoroughly clean oil pressure rel
34. er bore 2 Position stylus of gauge to cylinder block top face on edge of number 1 cylinder bore zero gauge 3 Rotate crankshaft in a clockwise direction until numbers 1 and 4 pistons are at TDC 4 Position stylus of DTI gauge near edge of piston crown measure and record number 1 piston stand proud Measurement must be taken at front and rear of piston and highest protrusion figure recorded 5 Repeat above procedures for remaining pistons OVERHAUL 27 6 From all of the readings obtained determine highest protrusion figure and select the appropriate cylinder head gasket Protrusion 0 50 to 0 60 mm select gasket with 1 identification hole Protrusion 0 61 to 0 70 mm select gasket with 2 identification holes Protrusion 0 71 to 0 80 mm select gasket with 3 identification holes Protrusion 0 81 to 0 90 mm select gasket with 0 identification holes NOTE Identification holes are located on A the edge of the gasket 7 8 28 Remove DTI Rotate crankshaft in a clockwise direction until all pistons are half way up cylinder bores OVERHAUL ENGINE Cylinder head refit 1 Ensure that mating faces of cylinder head and block are clean and dry and that 2 locating dowels are fitted in cylinder block Lubricate threads of new cylinder head bolts with engine oil Check that cylinder head bolt holes in cylinder block are clean and dry Rotate crankshaft in a clockwise direction until
35. finger tighten 2 bolts ensuring that thermostatic valve remains correctly positioned in extension housing Tighten bolts to 9 Nm OVERHAUL 37 ENGINE Oil filter head refit 1 Remove all traces of gasket from oil filter head 38 and cylinder block using suitable gasket removal spray and a plastic scraper 12M2896 Smear a new gasket with engine oil and position on oil filter head Fit oil filter head fit 4 bolts and tighten to 45 Nm Smear sealing ring of new oil filter element with engine oil and fit to oil filter head Plug open pipe connections to prevent ingress of dirt OVERHAUL FUEL INJECTION PUMP Remove 1 Remove timing belt 2 Remove fuel pipes from pump and injectors 12M2935 3 Ensure that timing pin LRT 12 045 is inserted in injection pump gear hub plate and injection pump hub 4 Remove 3 bolts securing hub and injection pump gear to injection pump remove timing pin LRT 12 045 and gear CAUTION Do not remove nut securing hub to pump SS 12M293 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 inje
36. ght hand pressure CAUTION Remove the minimum amount of material necessary to obtain correct valve seat face Smear Prussian Blue to seating face of a correctly ground valve Insert valve into guide and press it firmly without rotating on to seat insert remove valve Check that an even line of Prussian Blue has been transferred to centre of valve seat insert continue cutting operation as necessary until this has been achieved Upon completion remove all traces of swarf ENGINE Bees Valve seat inserts renew 1 2 3 Remove original valve seat insert taking care not to damage cylinder head Thoroughly clean valve seat insert recess Heat cylinder head to 65 C WARNING Take care when handling hot A cylinder head Place cylinder head on bed of hand press and using a suitable mandrel press replacement seat insert into recess Allow cylinder head to air cool Check that seat insert is seated squarely in recess OVERHAUL 25 ENGINE Lapping in valves Valve head stand down checking 1 Lap each valve to its seat using grinding paste 2 Apply Prussian Blue to valve seat insert Insert valve into guide and press it firmly without rotating on to seat 12M2913 3 Remove valve and check that a continuous even line of Prussian Blue has been transferred to valve face continue lapping in valve as necessary NOTE Line does not have to be across A whole width of valve face
37. ghten each pair of main bearing cap bolts to 133 Nm in the order No 2 No 4 No 1 and No 5 Check that crankshaft rotates freely and smoothly after tightening each pair of bolts 12M2948 Remove seal guides LRT 12 035 and select feeler gauges to a thickness of 0 80 mm position gauges on number 5 main bearing cap adjacent to oil seals Position a sharp blade on feeler gauges and keeping blade parallel to bearing cap slice excess material off oil seal Repeat above procedures for remaining seal CAUTION Seals should be left to settle for as long as possible before they are trimmed OVERHAUL ENGINE Big end bearings 1 Lubricate big end bearing shells and crankshaft journals with engine oil Fitnumbers 1 and 4 big end bearing caps and shells fit bearing cap nuts and tighten to 59 Nm 0 2 2 P 12 2968 Move numbers 1 and 4 connecting rods fully to one side of crankshaft journal and using feeler gauges check end float of both connecting rods on journals is between 0 15 and 0 35 mm If end float is outside limits replace connecting rod Check that crankshaft rotates smoothly Repeat above procedures for numbers 2 and 3 big end bearings ENGINE 99 4 Slide oil seal protector sleeve over crankshaft Crankshaft rear oil seal refit fit oil seal and housing over guide studs and crankshaft fit and finger tighten 3 bolts 1 Ensure that oil seal runn
38. ief valve plunger spring and relief valve bore then lubricate components with engine oil Insert plunger and spring into bore Smear threads of relief valve plug with Loctite 57T Fit plug and tighten to 17 Nm OVERHAUL 33 34 ENGINE Timing belt rear cover refit 1 Remove all traces of gasket material from cylinder block using suitable gasket removal spray and a plastic scraper 2 Screw 2 slave guide studs into cylinder block 3 Fit new gasket over guide studs OVERHAUL 25mm 80mm 12 2878 4 Note position of oil pump drive flats on crankshaft 5 Rotate oil pump inner rotor to align with drive flats on crankshaft and position timing belt rear cover on guide studs 6 Fit timing belt rear cover CAUTION Do not remove guide studs at this stage 7 Fit 8 bolts of the correct length in positions shown remove guide studs and fit remaining 2 bolts ENGINE Besos CONS 12 2879 5 2 8 10 8 Using sequence shown tighten bolts to 25 Nm 9 Fit oil pick up pipe and sump 10 Lubricate a new crankshaft front oil seal with engine oil 12M2882 13 Fit oil seal using tool LRT 12 082 14 Fit fuel injection pump 15 Fit timing belt tensioner and gears 12 2881 LRT 12 079 11 Fit oil seal using tool LRT 12 079 12 Lubricate a new camshaft oil seal with engine oil OVERHAUL 35 ENGINE OIL FILTER HEAD Remove 12M2893 1 1 Remove and discard oil filter element 2
39. ing belt to Used belt 12 Nm New belt 15 Nm refitted ensure direction of rotation mark is facing correct way 4 Keeping timing belt at the correct tension timing gears tighten tensioner bolt to 45 Nm crankshaft OVERHAUL ENGINE Bees LRT 12 077 16 LRT 1 NN IN 16 Support timing belt front cover on suitable 12M2859 blocks of wood 17 Smear a new crankshaft oil seal with engine oil 18 Using tool LRT 12 077 fit oil seal from inside face of front cover 12M2858 5 Check that timing pin LRT 12 045 moves freely in and out of injection pump hub if pin 35mm 110mm 35mm does not move freely slacken 3 bolts move gear slightly and re check 25mm 50mm 100mm 6 When timing pin moves freely tighten 3 bolts to 25 Nm 7 Remove timing pin LRT 12 045 and flywheel drive plate locking tool LRT 12 044 8 Rotate crankshaft twice in a clockwise direction using crankshaft pulley bolt until flywheel drive plate locking tool LRT 12 044 can be refitted 9 Slacken timing belt tensioner securing bolt and re tension timing belt 10 Tighten tensioner bolt to 45 Nm 11 Fit timing pin LRT 12 045 into 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 12M2860 110mm 100mm 35mm
40. ing surface on recover oil seal protector sleeve crankshaft and oil seal housing mating surface on cylinder block are clean and oil free and that CAUTION Do not lubricate oil seal or bolt holes in cylinder block are clean and dry running surface on crankshaft Do not separate protector sleeve from oil seal and do not touch lip of seal If protector sleeve is removed or seal is inadvertently handled it must not be fitted as the coating applied to the oil seal during manufacture will be destroyed and oil leakage will result 5 Remove 2 guide studs fit and finger tighten remaining 2 bolts 6 Tighten 5 bolts by diagonal selection to 25 Nm 12M2949 2 Screw 2 slave guide studs into cylinder block 3 Position new gasket to cylinder block ensuring that groove along bottom edge of gasket is towards block NOTE O ring fitted to early engines is no longer required OVERHAUL 65 ENGINE Pistons and connecting rods remove 1 Remove big end bearings 2 Suitably identify each piston to its respective cylinder bore check that arrow on piston crown is pointing towards front of cylinder block if arrow 15 not visible suitably mark piston 3 Check that plastic tubing is fitted to connecting rod bolts 4 Push each piston and connecting rod up cylinder bore until they can be withdrawn 5 Remove big end bearing shells from connecting rods CAUTION Big end bearing shells should A always be renewed 6 Inspect pisto
41. l illustrated 12 13 14 15 16 Manual gearbox Rotate crankshaft clockwise using crankshaft pulley bolt until tool LRT 12 044 can be inserted in slot in flywheel Automatic gearbox Rotate crankshaft clockwise using crankshaft pulley bolt until tool LRT 12 044 can be inserted in slot in drive plate LRT 12 045 15 14 12M2855 16 Check that crankshaft Woodruff key is aligned with arrow on timing belt rear cover If necessary rotate camshaft timing gear using the centre bolt until timing mark on gear is aligned with timing mark on timing belt rear cover Remove crankshaft pulley bolt OVERHAUL 7 ENGINE Timing belt refit and adjust tension Refit 8 Using the fingers only fit a new timing belt to Fit idler pulley Fit idler pulley nut and tighten to 45 Nm Ensure that timing belt is correctly located on Check that tensioner pulley bolt is finger tight Temporarily fit crankshaft pulley bolt to Adjust tension 1 Ensure tools LRT 12 044 and LRT 12 045 are still fitted 12M2856 timing gears keeping slack portion of belt on idler pulley side of belt If necessary rotate fuel injection pump gear anti clockwise to align 12M2857 4 gear teeth with those of timing belt CAUTION If original timing belt is to be 2 Position a dial type torque wrench and suitable extension to hole in tensioner bracket keeping the torque wrench positioned vertically 3 Tension tim
42. linder head Position distance piece tool LRT 12 515 and valve guide replacer LRT 12 046 to valve guide Press valve guide into cylinder head until distance piece contacts face of head remove tools Allow cylinder head to air cool ENGINE Bees Valve seat inserts refacing CAUTION Prior to refacing valve seats check valve head stand down If after refacing valve head stand down will be below limits seat inserts must be replaced LRT 12 502 12M2907 Support cylinder head on its side on suitable blocks of wood Loosely assemble pilot tool LRT 12 502 and a suitable expandable collet ensuring that chamfered end of expander is towards the collet OVERHAUL 23 ENGINE 24 Lightly lubricate the tool with engine oil Insert pilot into valve guide from combustion chamber side of cylinder head until shoulder of pilot contacts guide Check that collet is fully inserted into valve guide and expand collet against the guide using a suitable tommy bar OVERHAUL LRT 12 501 MS 621 45 6 Assemble the 45 cutter MS621 exhaust valves and 60 cutter MS627 inlet valves to tool LRT 12 501 7 Position tool LRT 12 501 and appropriate cutter to valve seat insert to be refaced 8 Using the Allen key adjust position of cutter so that centre of cutter contacts area of seat insert to be cut 9 10 11 12 13 12 2910 Cut valve seat insert using li
43. lly rearwards and zero gauge Pull camshaft fully forwards and check that end float is between 0 1 and 1 2 mm If end float exceeds 0 2 mm with new thrust plate fitted camshaft must be replaced Remove DTI and timing gear Lubricate components of each cam follower with engine oil Lubricate cam follower bores with engine oil OVERHAUL 75 ENGINE 15 16 17 18 19 20 21 22 23 76 12M2956 Insert each cam follower guide into its original location in the cylinder block Fit new retaining bolt locate end of bolt in cam follower guide Tighten bolt to 14 Nm Fit roller ensuring that reference mark made during removal is towards front of cylinder block Fit cam follower slide ensuring that word FRONT mark F is towards front of cylinder block Repeat above procedures for remaining cam follower assemblies Fit a dry new gasket to baffle plate Fit baffle plate fit 3 bolts and finger tighten in their original locations Bolts are tightened when fuel injection pump is fitted OVERHAUL Cylinder block inspection 1 2 3 Thoroughly clean cylinder block ensure all bolt holes are clean and dry Remove all traces of carbon from cylinder head gasket face Remove all traces of gaskets using suitable gasket removal spray and a plastic scraper Check all studs for damage replace as necessary Check core plugs for corrosion and signs of leakage replace
44. lock 3 Remove 4 bolts securing housing to engine mountings 4 Progressively slacken then remove 6 bolts securing housing to cylinder block 5 Remove housing OVERHAUL 53 ENGINE Refit 1 Remove all traces of sealant from mating faces of housing and cylinder block using solvent from kit GUG 705548GM 5 Using sequence shown tighten bolts to 45 Nm 12M2891 NOTE If engine mounting bolts were not fitted omit bolts 8 10 11 and 12 from tightening sequence and re number 2 Apply a bead of sealant from kit to cylinder accordingly block 3 Position housing to cylinder block 6 Fit flywheel drive plate 4 Fit and finger tighten bolts 54 OVERHAUL CRANKSHAFT CAMSHAFT PISTONS AND CYLINDER BLOCK NOME ob Remove timing belt rear cover Remove flywheel drive plate housing Remove fuel lift pump Remove cylinder head Remove sump oil pick up and drain pipes Remove oil filter head Remove brake servo vacuum pump ENGINE Bees Crankshaft rear oil seal remove Remove 5 bolts securing rear oil seal housing to cylinder block Remove and discard oil seal and housing Early engines Remove and discard O ring Remove and discard gasket OVERHAUL 55 ENGINE Big end bearings remove 12M2924 1 Suitably identify each oil jet tube to its fitted location 2 Remove bolt securing each oil jet tube assembly to cylinder block 3 Remove oil jet tube assemblie
45. n of Plastigage indicates main bearing clearance Main bearing clearance 0 031 to 0 079 mm 60 OVERHAUL 8 If main bearing clearances are incorrect use a combination of standard and oversize main bearing shells and re check clearances CAUTION Keep main bearing shells A selected in their fitted order 9 Remove all traces of Plastigage using an oily rag 10 Using assistance remove crankshaft 11 Remove upper main bearing shells and keep in their fitted order Crankshaft end float checking 1 Lubricate upper main bearing shells and crankshaft main bearing journals with engine oil 2 Lubricate new standard size thrust washers with engine oil and position washers in recess in centre main bearing saddle NOTE Grooved side of washers must face ZN outwards ENGINE Bees Using assistance fit crankshaft Attach a DTI to rear face of cylinder block with stylus contacting end of crankshaft push crankshaft fully rearwards and zero gauge Push crankshaft fully forwards and measure end float If end float exceeds 0 05 0 15 mm remove crankshaft fit combinations of standard and oversize thrust washers to achieve correct end float CAUTION Variations of thrust washer thicknesses on each side of crankshaft must not exceed 0 08 mm When end float is correct remove DTI Using assistance remove crankshaft and thrust washers Ensure that thrust washers are identified to their l
46. ns and connecting rods 66 OVERHAUL Piston rings remove 1 2 Using a suitable expander remove and discard piston rings Using a squared off end of an old piston ring remove carbon from piston ring grooves ENGINE Bees Pistons and connecting rods inspection Pistons remove 1 Remove carbon from piston using fine emery FS cloth soaked in oil 2 3 S 12M2958 2 Measure and record piston diameter at right 12M2957 angles to gudgeon pin hole mid way between hole and bottom of skirt Piston diameter Standard 90 395 mm 1 Suitably identify each piston to its connecting 1st oversize 90 649 mm rod note position of bearing shell tag recess in 2nd oversize 90 903 mm connecting rod relative to arrow on piston crown 2 Remove and discard circlips retaining gudgeon pin 3 Push gudgeon pin out of piston remove connecting rod Retain gudgeon pins and connecting rods with their respective pistons OVERHAUL 67 ENGINE 68 FRONT or 4 12M2959 Starting with number 1 piston invert piston and with arrow on piston crown pointing towards REAR of cylinder block insert piston into number 1 cylinder bore until bottom of skirt is 30 mm from top of bore Using feeler gauges check clearance between left hand side of piston and cylinder bore 0 075 mm viewed from front of cylinder block Repeat above procedures for remaining pistons If piston to cylinder bore clearance
47. ocation OVERHAUL 61 ENGINE Big end bearing clearance checking 10 A 11 12 62 1 Fit pistons and connecting rods 2 3 Fit big end bearing shells to connecting rods Degrease new big end bearing shells ensuring that tag is located in recess in connecting rod Fit big end bearing shells to bearing caps ensuring that tag is located in recess in cap Temporarily fit crankshaft pulley bolt and rotate crankshaft to bring numbers 1 and 4 journals to BDC Remove all traces of oil from crankshaft journals Pull numbers 1 and 4 connecting rods on to crankshaft journals remove plastic tubing from connecting rod bolts 9 P x 8 12M2967 Place a strip of Plastigage across width of numbers 1 and 4 big end journals Fit bearing caps and shells to connecting rods ensuring that reference marks on caps and rods are aligned Fit big end bearing cap nuts and tighten to 59 Nm CAUTION Do not rotate crankshaft Remove big end bearing caps and shells Measure widest portion of Plastigage on crankshaft journals using the scale supplied the graduation that corresponds to the widest portion of Plastigage indicates big end bearing clearance Big end bearing clearance 0 025 to 0 075 mm OVERHAUL 13 If big end bearing clearances are incorrect use a combination of standard and oversize bearing shells and re check clearance CAUTION Retain selected shells with their N
48. od bolt Big end bearing shell Push rod Cam follower slide Roller Cam follower guide Guide retaining bolt Dipstick Dipstick tube Dipstick tube bolt ENGINE esssi Camshaft Oil jet tube Drive pin Camshaft thrust plate Camshaft bearings Main bearing shell Baffle plate Core plugs Oil pressure switch Thermostatic valve assembly Oil filter head Fuel lift pump Fuel lift pump gaskets Spacer if fitted Brake servo vacuum pump Crankcase breather pipe Oil filter head gasket Baffle plate gasket OU filter element DESCRIPTION AND OPERATION 3 ENGINE CRANKSHAFT SUMP AND OIL PUMP Crankshaft Woodruff key Main bearing shell Main bearing cap front Main bearing cap bolt O ring oil pick up pipe Oil pick up pipe and strainer Sump bolt Oil drain pipe 10 Sump 11 Gasket oil drain pipe 12 Main bearing cap rear 13 Rear main bearing cap oil seal ENGINE Bees Crankshaft thrust washers Main bearing cap centre Big end bearing cap Big end bearing cap nut Big end bearing shell Oil jet tube banjo bolt OU jet tube Oil pump Timing belt rear cover Plug Oil pressure relief valve spring Oil pressure relief valve plunger DESCRIPTION AND OPERATION 5 ENGINE 12M3636 DESCRIPTION AND OPERATION 6 ROCKER SHAFT AND COVER
49. om bearing caps 6 Using assistance remove crankshaft ENGINE 99 7 Recover grooved thrust washers and upper main bearing shells CAUTION Main bearing shells and thrust washers must always be replaced 8 Remove pistons and connecting rods OVERHAUL 57 ENGINE Crankshaft inspection NOTE Crankshafts may be reground 0 25 mm undersize on both main and big end journals See Crankshaft regrinding Clean crankshaft and main bearing caps ensure oilways are clear Check main and big end journals for signs of scoring excessive wear and overheating 3 ei Be 12 2939 Check main and big end bearing journals for wear and ovality make 3 checks at 120 intervals in centre of journals Maximum ovality 0 040 mm Main bearing journal diameter 63 475 to 63 487 mm Service limit 63 36 mm Regrind diameter 63 225 to 63 237 mm Big end bearing journal diameter 58 725 to 58 744 mm Service limit 58 637 mm Regrind diameter 58 475 to 58 494 mm If bearing journal diameters are less than service limit crankshaft may be reground to specified regrind diameter and 0 25 mm oversize bearing shells fitted OVERHAUL 12M2940 Using a micrometer measure diameter at each end of main and big end bearing journals From measurements obtained calculate taper of each journal Maximum journal taper end to end 0 025 mm 12M2941 Support each end of crankshaft in Vee blocks
50. ove bolt securing timing belt tensioner pulley move pulley until tension is removed from belt Remove nut and washer securing idler pulley Release idler pulley from timing belt remove pulley Release timing belt from gears discard belt OVERHAUL 3 ENGINE Timing belt tensioner and timing gears remove LRT 12 078 12M2846 1 Remove crankshaft gear using tools LRT 12 031 and LRT 12 078 recover Woodruff key from crankshaft 2 Remove and discard O ring 3 Remove bolt and slotted washer securing timing belt tensioner pulley remove pulley together with tensioner bracket 4 Recover flanged spacer from idler pulley stud 4 OVERHAUL 12M2848 5 5 Remove centre bolt and washer securing camshaft timing gear remove gear and hub plate as an assembly NOTE Later engines are fitted with a flange head bolt CAUTION Do not remove 3 bolts securing hub plate to gear LRT 12 045 O SAI OR 2 12 2849 6 8 le 6 Remove 3 bolts securing fuel injection pump gear and hub plate to pump hub CAUTION Do not remove nut securing hub to fuel injection pump 7 Remove timing pin LRT 12 045 8 Remove fuel injection pump gear and hub plate ENGINE Bees Inspecting components Check timing gear teeth for burrs Remove all traces of gasket from timing belt front and rear covers using suitable gasket removal spray and a plastic scraper OVERHAUL 5 ENGI
51. res specialist information and useful assembly details WARNINGS CAUTIONS and Notes have the following meanings WARNING Procedures which must be followed precisely to avoid the possibility of injury CAUTION Calls attention to procedures which must be followed to avoid damage to components NOTE Gives helpful information INTRODUCTION References With the engine and gearbox assembly removed the crankshaft pulley end of the engine is referred to as the front Operations covered in this manual do not include reference to testing the vehicle after repair It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned Dimensions The dimensions quoted are to design engineering specification with Service limits where applicable INTRODUCTION 1 INTRODUCTION REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Land Rover recommended parts are used Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories Safety features and corrosion prevention treatments embodied in the car may be impaired if other than Land Rover recommended parts are fitted In certain territories legislation prohibits the fitting of parts not to the manufacturer s specification Torque wrench setting figures giv
52. rt a slave bolt into pedestals 1 and 5 to prevent components sliding off shaft 9 Remove rocker shaft assembly OVERHAUL 11 ENGINE Rocker shaft dismantling 1 Suitably identify each component to its fitted position 10 Withdraw push rods 11 Remove valve caps CAUTION Keep push rods and valve caps A in their fitted order 12M2970 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 12 OVERHAUL Inspecting components 1 2 10 11 Measure and record diameter of rocker shaft at one of the pedestal locations Measure and record diameter of rocker shaft at each of the rocker arm locations 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 Check rocker arm pads for signs of wear replace rocker arms as necessary 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 Check that each nut runs freely on adjusting screw threads Check each push rod for signs of wear and for straightness replace as necessar
53. s A 4 Recover sealing washers NOTE Dowel located CAUTION Oil jet tube bolts incorporate a A non return valve 5 Temporarily fit crankshaft pulley bolt 6 Suitably identify fitted position of each big end bearing cap to its connecting rod and each connecting rod to its respective cylinder bore 56 OVERHAUL 8 12M2925 7 Rotate crankshaft to bring numbers 1 and 4 connecting rods to BDC 8 Remove and discard 2 nuts securing each big end bearing cap 9 Remove numters 1 and 4 big end bearing caps recover bearing shells 10 Slide suitable pieces of plastic tubing over each connecting rod bolt 11 Push numters 1 and 4 connecting rods up cylinder bores until they are clear of crankshaft journals 12 Repeat above procedures to remove numbers 2 and 3 big end bearings CAUTION Big end bearing shells must A always be replaced Crankshaft and main bearings remove 1 Suitably identify each main bearing cap and its fitted direction in crankcase 12M2926 2 Starting at number 3 main bearing cap and working outwards progressively slacken then remove bearing cap bolts Keep bolts with their respective main bearing caps 3 Using the fingers only rock each main bearing cap until it is released from its retaining dowels CAUTION Do not tap main bearing caps A sideways to release 4 Remove and discard oil seals from number 5 main bearing cap 5 Recover lower main bearing shells fr
54. s necessary Bearings must be replaced as a 561 5 Check cam follower slides rollers and cam follower guides for signs of wear 6 Check that each slide moves freely in its guide and that oilways are clear Cam followers must be replaced as an assembly 11 Remove 2 bolts securing camshaft thrust plate 7 Check that oil passage in oil jet tube is clear to cylinder block remove and discard plate 8 Insert a piece of stiff wire in end of oil jet tube 12 Carefully withdraw camshaft taking care not to and check that non return valve can be drop end of camshaft on to bearings depressed and closes under spring pressure 74 OVERHAUL Camshaft refit and check end float 1 Remove all traces of gasket from baffle plate and cylinder block using suitable gasket removal spray and a plastic scraper 2 Lubricate cams journals and bearings with engine oil 3 Ensure thrust plate bolt holes in cylinder block are clean and dry 4 Carefully insert camshaft into cylinder block taking care not to drop end of camshaft on to bearings 5 Fit a new thrust plate fit bolts and tighten to 9 Nm 10 11 Fit oil jet tube and tighten to 17 Nm 13 14 12M2955 Temporarily fit camshaft timing gear fit and tighten bolt sufficiently to pull gear fully on to camshaft Attach a magnetic base DTI to front of cylinder block with stylus of gauge contacting machined face of gear adjacent to gear teeth Push camshaft fu
55. ses through internal drillings in the cylinder block to an external full flow filter 5 Further drillings feed oil to the cylinder block main oil gallery 6 which in turn supplies the crankshaft main bearings 7 Cross drillings in the crankshaft carry oil to the connecting rod big end bearings 8 The camshaft bearings 9 are supplied with oil from the main oil gallery An internal oilway from the camshaft front bearing connects the cylinder block to the cylinder head and feeds oil to the rocker shaft assembly 10 lubricating the valves and springs The pistons gudgeon pins and small end bushes are lubricated and cooled by oil jets 11 which are supplied from the main oil gallery via relief valves which allow the oil to flow at a pre determined pressure Oil pressure is controlled by a pressure relief valve 12 incorporated in the timing case housing together with the oil pump The valve allows excess oil to be recirculated back into the oil feed gallery The rotor type oil pump is driven by 2 flats machined on the front of the crankshaft Oil cooling is maintained by an oil cooler which is integral with the radiator and linked to adaptors on the oil filter head by pre formed feed and return hoses A thermostatic valve in the filter head allows oil to flow to the cooler when it reaches a pre determined temperature ENGINE DESCRIPTION AND OPERATION 17 ENGINE 12M2836 Crankcase ventilation system A brea
56. sioner bolt Timing belt idler pulley nut Flywheel drive plate housing plug Timing belt front cover bolts Crankshaft pulley bolt Rocker shaft nuts and bolts Rocker cover nuts Crankcase breather cyclone unit bolt Rear timing cover bolts Oil pressure relief valve plug Flywheel bolts Drive plate bolts Drive plate to starter ring gear bolts Flywheel drive plate housing bolts Coolant outlet elbow bolts Thermostat housing bolts Oil filter head bolts Cylinder head bolts Stage 1 Stage 3 Stage 4 Bolts 1 2 7 8 9 10 15 16 17 and 18 only Sump drain plug Oil sump bolts Oil pick up pipe bolts To main bearing cap To timing belt rear cover Oil drain pipe bolts Fuel pump timing gear to hub plate bolts Injector clamp nut Spill return pipe banjo bolts Glow plugs Brake servo vacuum pump bolts Camshaft gear bolt Spill return pipe to injection pump banjo bolts Mounting bracket to fuel injection pump bolts Fuel injection pump and baffle plate to cylinder block bolts Crankshaft rear oil seal housing bolts Camshaft thrust plate bolts Camshaft oil jet tube Piston oil jet banjo bolts Cam follower guide bolts Big end bearing cap nuts Main bearing cap bolts ENGINE Bees 45 Nm 45 Nm 12 Nm 25 Nm 80 Nm then further 90 5 Nm then further 50 10 Nm 9 Nm 25 Nm 17 Nm 146 Nm 146 Nm 25 Nm 45 Nm 9 Nm 25 Nm 45 Nm 40 Nm Further 60 Further 60 Further 20 35 Nm 25 Nm 9 Nm 25 Nm 25 Nm 25 Nm 25 Nm 1
57. that raised pip on concave face of clamp faces upwards Fit and tighten injector clamp nut to 25 Nm Position spill return pipes to injector fit banjo bolt and 2 new sealing washers Tighten banjo bolt to 10 Nm Repeat above procedures for remaining injectors Position fuel pipes to injector and fuel injection pump tighten connections ENGINE 99 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 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 OVERHAUL 43 ENGINE BRAKE SERVO VACUUM PUMP Remove 1 Ensure that number 1 piston is at TDC CAUTION Rotate crankshaft in a N clockwise direction 12M2934 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 A air cleaner bracket removal 3 Remove bolts 4 Remove vacuum pump remove and discard gasket 44 OVERHAUL 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 A cleaner bracket is fitted
58. ther cyclone unit 1 fitted to the right hand side of the rocker cover controls the rate at which air is purged from the sump via a hose 2 from the camshaft side cover to the rocker cover and extracts 18 DESCRIPTION AND OPERATION x VELIT EHE 24 et 7 QUAS M d val 1 SA oil from the gaseous atmosphere The oil then drains back to the sump through a hose and flanged pipe connection 3 The residues are drained off from the top of the cyclone breather and pass through a hose 4 into the engine via the turbocharger where they are burned in the combustion chamber TIMING BELT TENSIONER AND GEARS Timing belt remove LRT 12 080 12M2838 1 Position tool LRT 12 080 to crankshaft pulley retain with 4 bolts 2 Restrain crankshaft using tool LRT 12 080 and remove crankshaft pulley flange head bolt NOTE Bolt and washer fitted to early engines 3 Remove tool LRT 12 080 ENGINE Bees LRT 12 049 12M2839 4 Position tool LRT 12 049 and thrust button part of tool LRT 12 031 to crankshaft pulley remove pulley recover Woodruff key 5 7 9 11 4 12M2840 5 Using sequence shown progressively slacken then remove 14 bolts securing timing belt front cover OVERHAUL 1 ENGINE 12M2841 6 6 Remove timing belt front cover 7 Remove and discard gasket 8 Remove and discard crankshaft front oil seal from timing belt front cover 9 Temporarily fit
59. tion 1 Check that oil passage in each oil jet tube is clear 2 Thoroughly clean banjo bolts 3 Insert a piece of stiff wire in end of banjo bolt and check that non return valve can be depressed to open position and returns to closed position under spring pressure CAUTION If non return valve is not A working correctly replace banjo bolt 4 Check sealing washers for damage replace as 12M2965 necessary Check ring to groove clearances Top compression 0 167 to 0 232 mm 2nd compression 0 05 to 0 08 mm Oil control rails 0 05 to 0 08 mm H new ring to groove clearances are excessive new pistons must be fitted OVERHAUL 71 ENGINE Pistons and connecting rods refit 1 Position piston ring gaps at 60 to each other and away from thrust side of piston left hand side of piston when viewed from front 2 Slide suitable lengths of tubing over connecting rod bolts 3 Ensure cylinder bores are clean 4 Lubricate pistons rings and cylinder bores with engine oil 12M2966 5 Compress piston rings using a suitable clamp 6 Insert piston and connecting rod into cylinder bore ensuring that piston is in its correct fitted order and arrow on piston crown is towards front of cylinder block 7 Push piston into cylinder bore CAUTION Ensure that connecting rods do not contact cylinder bores Do not pull connecting rods fully down cylinder bores at this stage 8 Repeat above procedures for
60. tioned 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 N until pipe is connected to fuel filter 12M2932 Remove 2 bolts securing fuel lift pump to cylinder block remove pump gasket spacer and 2nd gasket Discard gaskets OVERHAUL 41 ENGINE FUEL INJECTORS NO 22 Remove d XE T 22 218 d K 9 0000 s 12M2930 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 12 2929 washer WARNING Do not attempt to remove A injectors using engine compression 1 Disconnect each pair of fuel pipes from fuel either use an open ended spanner on injection pump and injectors 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 42 OVERHAUL Refit Clean all traces of carbon from injector ports Fita new sealing washer to injector insert injector into port ensuring that spill return banjo bolt hole faces away from cylinder head Position injector clamp to injector and cylinder head stud ensuring
61. y Check valve caps for signs of wear replace as necessary Check rocker arm bushes for scoring and wear Assemble each rocker arm to its fitted location on rocker shaft and check clearance of bush to shaft does not exceed 0 12 mm If clearance exceeds figure given bushes must be replaced ENGINE Bees Rocker arm bushes replace 12M2867 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 1 12 2868 4 Check that lubrication holes in each rocker are clear 5 Check that lubrication holes in rocker shaft are clear 6 Check spacers and washers for wear replace as necessary OVERHAUL 13 ENGINE Rocker shaft assembling 1 2 3 14 Lubricate all components with engine oil Assemble rocker arms spacers washers and pedestals to rocker shaft ensuring that they are in their original fitted positions Retain pedestals 1 and 5 with slave bolts OVERHAUL 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 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

300 TDi ENGINE OVERHAUL MANUAL

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