Land Rover engine 300 TDi. Manual — part 7
ENGINE
8
OVERHAUL
Timing belt - refit and adjust tension
Refit
1. Using the fingers only, fit a new timing belt to
timing gears keeping slack portion of belt on
idler pulley side of belt. If necessary, rotate fuel
injection pump gear anti-clockwise to align
gear teeth with those of timing belt.
CAUTION: If original timing belt is to be
refitted, ensure direction of rotation mark
is facing correct way.
2. Fit idler pulley.
3. Fit idler pulley nut and tighten to 45 Nm.
4. Ensure that timing belt is correctly located on
timing gears.
5. Check that tensioner pulley bolt is finger tight.
6. Temporarily fit crankshaft pulley bolt to
crankshaft.
Adjust tension
1. Ensure tools LRT-12-044 and LRT-12-045
are still fitted.
2. Position a dial type torque wrench and suitable
extension to hole in tensioner bracket keeping
the torque wrench positioned vertically.
3. Tension timing belt to :
Used belt - 12 Nm
New belt - 15 Nm
4. Keeping timing belt at the correct tension,
tighten tensioner bolt to 45 Nm.
ENGINE
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9
5. Check that timing pin LRT-12-045 moves
freely in and out of injection pump hub, if pin
does not move freely, slacken 3 bolts, move
gear slightly and re-check.
6. When timing pin moves freely, tighten 3 bolts
to 25 Nm.
7. Remove timing pin LRT-12-045 and
flywheel/drive plate locking tool LRT-12-044.
8. Rotate crankshaft twice in a clockwise direction
using crankshaft pulley bolt until flywheel/drive
plate locking tool LRT-12-044 can be refitted.
9. Slacken timing belt tensioner securing bolt and
re-tension timing belt.
10. Tighten tensioner bolt to 45 Nm.
11. Fit timing pin LRT-12-045 into fuel injection
pump gear hub plate and pump hub. If timing
pin cannot be inserted, slacken injection pump
gear bolts, rotate pump shaft using shaft nut
until pin slides easily into pump hub, Tighten
bolts to 25 Nm.
12. Tighten camshaft gear bolt to 80 Nm.
13. Remove timing pin and flywheel/drive plate
locking tools.
14. Fit plug to flywheel housing, tighten to 12 Nm.
15. Remove crankshaft pulley bolt.
16. Support timing belt front cover on suitable
blocks of wood.
17. Smear a new crankshaft oil seal with engine
oil.
18. Using tool LRT-12-077, fit oil seal from inside
face of front cover.
19. Fit a dry, new gasket to timing belt rear cover.
20. Position timing belt front cover to rear cover.
21. Fit bolts of the correct length in positions
shown.
ENGINE
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OVERHAUL
22. Tighten bolts in sequence shown to 25 Nm.
23. Lightly oil crankshaft spigot, fit Woodruff key
and crankshaft pulley.
24. Position tool LRT-12-080 to crankshaft pulley,
retain tool using 4 bolts.
25. Fit crankshaft pulley flange head bolt.
26. Restrain crankshaft and tighten bolt to 80
Nm,then further 90.
°
27. Remove tool LRT-12-080.
ENGINE
OVERHAUL
11
ROCKER SHAFT
Remove
1. Disconnect breather hoses from crankcase
breather cyclone unit.
2. Remove bolt securing cyclone unit to rocker
cover.
3. Remove cyclone unit, remove and discard ’O’
ring.
4. Disconnect breather hoses from cylinder block
and rocker cover.
5. Remove 3 flange nuts securing rocker cover,
recover sealing washers.
6. Remove rocker cover, remove and discard
gasket.
7. Slacken locknut on each tappet adjusting
screw, slacken adjusting screws until they are
clear of push rods.
8. Working from the centre outwards,
progressively slacken then remove 3 nuts and
2 bolts securing rocker shaft pedestals to
cylinder head.
CAUTION: Insert a slave bolt into
pedestals 1 and 5 to prevent components
sliding off shaft.
9. Remove rocker shaft assembly.
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