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 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. 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.
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 LimitedINTRODUCTION
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 1INTRODUCTION
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 INTRODUCTIONENGINE
This page is intentionally left blank
DESCRIPTION AND OPERATION 1ENGINE
2 DESCRIPTION AND OPERATIONENGINE
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 3ENGINE
4 DESCRIPTION AND OPERATIONENGINE
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 5ENGINE
6 DESCRIPTION AND OPERATION