Land Rover engine 300 TDi. Manual — part 24
ENGINE
76
OVERHAUL
15. Insert each cam follower guide into its original
location in the cylinder block.
16. Fit new retaining bolt, locate end of bolt in cam
follower guide.
17. Tighten bolt to 14 Nm.
18. Fit roller ensuring that reference mark made
during removal is towards front of cylinder
block.
19. Fit cam follower slide ensuring that word
’FRONT’ or mark ’F’ is towards front of cylinder
block.
20. Repeat above procedures for remaining cam
follower assemblies.
21. Fit a dry, new gasket to baffle plate.
22. Fit baffle plate, fit 3 bolts and finger tighten in
their original locations.
23. Bolts are tightened when fuel injection pump is
fitted.
Cylinder block - inspection
1. Thoroughly clean cylinder block, ensure all bolt
holes are clean and dry.
2. Remove all traces of carbon from cylinder head
gasket face.
3. Remove all traces of gaskets using suitable
gasket removal spray and a plastic scraper.
4. Check all studs for damage, replace as
necessary.
5. Check core plugs for corrosion and signs of
leakage, replace as necessary.
6. 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
7. Repeat measurements 50 mm from bottom of
each cylinder bore.
8. 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
OVERHAUL
77
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.
ENGINE
DATA, TORQUE & TOOLS
1
ENGINE DATA
Rocker shaft
Rocker shaft wear - maximum
0.025 mm
. . . . . . . . . . . . . . . . . .
Rocker arm shaft to bush clearance - maximum
0.12 mm
. . . .
Valve clearance - inlet and exhaust
0.20 mm
. . . . . . . . . . . . . .
Oil pump
Outer rotor to housing clearance
0.025 to 0.075 mm
. . . . . . . . . . . . . . . .
Inner to outer rotor clearance
0.025 to 0.075 mm
. . . . . . . . . . . . . . . . . .
Outer rotor end-float
0.026 to 0.135 mm
. . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve spring free length
68.0 mm
. . . . . . . . . . . . . . . . . .
Cylinder head
Cylinder head maximum warpage
0.08 mm
. . . . . . . . . . . . . . .
Maximum movement of valve to guide
0.15 mm
. . . . . . . . . . .
Valve stem diameter:
Inlet
7.96 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
7.94 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head stand down:
Inlet
0.81 to 1.09 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
0.86 to 1.14 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve seat insert face angle:
Inlet
60
°
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
45
°
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve face angle:
Inlet
60
°
00’ to 60
°
30’
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
45
°
00’ to 45
°
30’
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve spring free length
46.28 mm
. . . . . . . . . . . . . . . . . . . . . . .
Timing belt tension on torque wrench
Used belt
12 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New belt
15 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive plate - automatic gearbox
Setting height
12.4 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
2
DATA, TORQUE & TOOLS
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 limit
63.36 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regrind diameter
63.225 to 63.237 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big-end journal diameter
58.725 to 58.744 mm
. . . . . . . . . . . . . . . . . . . . . .
Service limit
58.637 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regrind diameter
58.475 to 58.494 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main and 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:
1st oversize
0.063
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd oversize
0.127 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big-end bearing clearance
0.025 to 0.075 mm
. . . . . . . . . . . . . . . . . . . . .
Connecting rod end-float
0.15 to 0.35 mm
. . . . . . . . . . . . . . . . . . . . . .
Camshaft
End-float
0.1 to 0.2 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and connecting rods
Piston diameter:
Standard
90.395 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st oversize
90.649 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd oversize
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 rails
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
90.47 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For 1st oversize piston
90.73 mm
. . . . . . . . . . . . . . . . . . . . . . .
For 2nd oversize piston
90.98 mm
. . . . . . . . . . . . . . . . . . . . . . .
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