Land Rover engine 300 TDi. Manual — part 21
ENGINE
64
OVERHAUL
8. Tighten centre main bearing cap bolts to 133
Nm.
9. Temporarily fit crankshaft pulley bolt and check
that crankshaft rotates freely and smoothly.
10. Tighten 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.
11. 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.
12. Position a sharp blade on feeler gauges and
keeping blade parallel to bearing cap, slice
excess material off oil seal
13. Repeat above procedures for remaining seal.
CAUTION: Seals should be left to settle for
as long as possible before they are
trimmed.
Big-end bearings
1. Lubricate big-end bearing shells and
crankshaft journals with engine oil.
2. Fit numbers 1 and 4 big-end bearing caps and
shells, fit bearing cap nuts and tighten to 59
Nm.
3. 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.
4. If end-float is outside limits, replace connecting
rod.
5. Check that crankshaft rotates smoothly.
6. Repeat above procedures for numbers 2 and 3
big-end bearings.
ENGINE
OVERHAUL
65
Crankshaft rear oil seal - refit
1. Ensure that oil seal running surface on
crankshaft and oil seal housing mating surface
on cylinder block are clean and oil free and that
bolt holes in cylinder block are clean and dry.
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.
4. Slide oil seal protector sleeve over crankshaft,
fit oil seal and housing over guide studs and
crankshaft, fit and finger tighten 3 bolts,
recover oil seal protector sleeve.
CAUTION: Do not lubricate oil seal or
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.
ENGINE
66
OVERHAUL
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 is 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
always be renewed.
6. Inspect pistons and connecting rods.
Piston rings - remove
1. Using a suitable expander, remove and discard
piston rings.
2. Using a squared-off end of an old piston ring,
remove carbon from piston ring grooves.
ENGINE
OVERHAUL
67
Pistons - remove
1. Suitably identify each piston to its connecting
rod, note position of bearing shell tag recess in
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.
Pistons and connecting rods - inspection
1. Remove carbon from piston using fine emery
cloth soaked in oil.
2. Measure and record piston diameter at right
angles to gudgeon pin hole mid-way between
hole and bottom of skirt.
Piston diameter:
Standard = 90.395 mm
1st oversize = 90.649 mm
2nd oversize = 90.903 mm
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