OVERHAUL MANUAL

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 Ó 1997 Rover Group LimitedINTRODUCTION INTRODUCTION References How to use this manual With the engine and gearbox assembly removed, the crankshaft pulley end of the engine is referred to To assist in the use of this manual the section title is as the front. given at the top and the relevant sub-section is given at the bottom each page. Operations covered in this manual do not include reference to testing the vehicle after repair. It is This manual contains procedures for overhaul of the essential that work is inspected and tested after engine. For all other information regarding completion and if necessary a road test of the adjustments, removal of oil seals and engine, vehicle is carried out particularly where safety consult the Repair Manual for the model concerned. related items are concerned This manual is divided into 3 sections: Dimensions Description and Operation, Overhaul and The dimensions quoted are to design engineering Data, Torque & Tools. specification with Service limits where applicable. 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 figures, 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 1INTRODUCTION REPAIRS AND REPLACEMENTS SPECIFICATION When replacement parts are required it is essential Land Rover are constantly seeking to improve the that only Land Rover recommended parts are used. specification, design and production of their vehicles and alterations take place accordingly. While every Attention is particularly drawn to the following points effort has been made to ensure the accuracy of this concerning repairs and the fitting of replacement Manual, it should not be regarded as an infallible parts and accessories. guide to current specifications of any particular component or vehicle. Safety features and corrosion prevention treatments embodied in the car may be impaired if other than This Manual does not constitute an offer for sale of Land Rover recommended parts are fitted. In certain any particular component or vehicle. Land Rover territories, legislation prohibits the fitting of parts not Dealers are not agents of the Company and have no to the manufacturer’s specification. authority to bind the manufacturer by any expressed or implied undertaking or representation. Torque wrench setting figures given 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ENGINE This page is intentionally left blank DESCRIPTION AND OPERATION 1ENGINE 2 DESCRIPTION AND OPERATIONENGINE CYLINDER BLOCK, PISTONS AND CAMSHAFT 1. Top compression ring 20. Camshaft 2. 2nd ring 21. Oil jet tube 3. Oil control ring 22. Drive pin 4. Piston 23. Camshaft thrust plate 5. Gudgeon pin circlips 24. bearings 6. pin 25. Main bearing shell 7. Connecting rod 26. Baffle plate 8. Brake servo vacuum pump gasket 27. Core plugs 9. Core plug 28. Oil pressure switch 10. Connecting rod bolt 29. Thermostatic valve assembly 11. Big-end bearing shell 30. Oil filter head 12. Push rod 31. Fuel lift pump 13. Cam follower slide 32. Fuel lift pump gaskets 14. Roller 33. Spacer - if fitted 15. Cam follower guide 34. Brake servo vacuum pump 16. Guide retaining bolt 35. Crankcase breather pipe 17. Dipstick 36. Oil filter head gasket 18. tube 37. Baffle plate gasket 19. Dipstick tube bolt 38. Oil filter element DESCRIPTION AND OPERATION 3ENGINE 4 DESCRIPTION AND OPERATIONENGINE CRANKSHAFT, SUMP AND OIL PUMP 1. Crankshaft 14. Crankshaft thrust washers 2. Woodruff key 15. Main bearing cap - centre 3. Main bearing shell 16. Big-end bearing cap 4. Main cap - front 17. cap nut 5. Main bearing cap bolt 18. Big-end bearing shell 6. ’O’ ring - oil pick-up pipe 19. Oil jet tube banjo bolt 7. Oil pick-up pipe and strainer 20. Oil jet tube 8. Sump bolt 21. Oil pump 9. Oil drain pipe 22. Timing belt rear cover 10. Sump 23. Plug 11. Gasket - oil drain pipe 24. Oil pressure relief valve spring 12. Main bearing cap - rear 25. Oil relief valve plunger 13. Rear main bearing cap oil seal DESCRIPTION AND OPERATION 5ENGINE 6 DESCRIPTION AND OPERATION