Land Rover engine 300 TDi. Manual — part 15
ENGINE
40
OVERHAUL
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.
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.
FUEL LIFT PUMP
Remove
1. Disconnect fuel delivery pipe from fuel lift
pump, discard sealing washers.
CAUTION: Plug open connections to
prevent ingress of dirt.
ENGINE
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41
2. Remove 2 bolts securing fuel lift pump to
cylinder block, remove pump, gasket, spacer
and 2nd gasket.
3. Discard gaskets.
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 positioned 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
until pipe is connected to fuel filter.
ENGINE
42
OVERHAUL
FUEL INJECTORS
Remove
1. Disconnect each pair of fuel pipes from fuel
injection pump and injectors.
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
washer.
WARNING: Do not attempt to remove
injectors using engine compression,
either use an open ended spanner on
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.
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43
Refit
1. Clean all traces of carbon from injector ports.
2. Fit a new sealing washer to injector, insert
injector into port ensuring that spill return banjo
bolt hole faces away from cylinder head.
3. Position injector clamp to injector and cylinder
head stud ensuring that raised ’pip’ on concave
face of clamp faces upwards.
4. Fit and tighten injector clamp nut to 25 Nm.
5. Position spill return pipes to injector, fit banjo
bolt and 2 new sealing washers.
6. Tighten banjo bolt to 10 Nm.
7. Repeat above procedures for remaining
injectors.
8. Position fuel pipes to injector and fuel injection
pump, tighten connections.
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.
Refit
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.
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