Land Rover engine 300 TDi. Manual — part 23
ENGINE
72
OVERHAUL
Pistons and connecting rods - refit
1. Position piston ring gaps at 60
°
to each other
and away from thrust side of piston (left hand
side of piston when viewed from front).
2. Slide suitable lengths of tubing over connecting
rod bolts.
3. Ensure cylinder bores are clean.
4. Lubricate pistons, rings and cylinder bores with
engine oil.
5. Compress piston rings using a suitable clamp.
6. Insert piston and connecting rod into cylinder
bore ensuring that piston is in its correct fitted
order and arrow on piston crown is towards
front of cylinder block.
7. Push piston into cylinder bore.
CAUTION: Ensure that connecting rods do
not contact cylinder bores. Do not pull
connecting rods fully down cylinder bores
at this stage.
8. Repeat above procedures for numbers 2 and 3
pistons and connecting rods.
Oil jet tubes - refit
1. Position sealing washers in cylinder block.
2. Fit oil jet tubes to their original locations.
3. Fit banjo bolts and washers, tighten bolts to 17
Nm.
ENGINE
OVERHAUL
73
Camshaft - remove
1. Remove oil jet tube.
2. Clean area around baffle plate.
3. Note fitted position of 3 bolts securing baffle
plate.
4. Remove 3 bolts securing baffle plate to
cylinder block, remove plate.
5. Remove and discard gasket.
CAUTION: Do not remove cam follower
guide retaining bolts until slides and
rollers have been removed, keep
components of each cam follower assembly in
their fitted order.
6. Using long nosed pliers, remove cam follower
slide.
7. Remove roller and suitably identify which side
of roller faces towards front of cylinder block.
8. Remove and discard bolt retaining cam
follower guide.
9. Remove cam follower guide.
10. Repeat above procedures for remaining cam
follower assemblies.
ENGINE
74
OVERHAUL
11. Remove 2 bolts securing camshaft thrust plate
to cylinder block, remove and discard plate.
12. Carefully withdraw camshaft taking care not to
drop end of camshaft on to bearings.
Camshaft, bearings and cam followers -
inspection
1. Check camshaft cams and bearing journals for
overheating, wear and scoring, replace
camshaft if necessary.
2. If camshaft is replaced, new bearings must be
fitted.
3. Check timing gear drive pin for security.
4. Check camshaft bearings for overheating, wear
and scoring and that lubrication holes are
clear, replace as necessary. Bearings must be
replaced as a set.
5. Check cam follower slides, rollers and cam
follower guides for signs of wear.
6. Check that each slide moves freely in its guide
and that oilways are clear. Cam followers must
be replaced as an assembly.
7. Check that oil passage in oil jet tube is clear.
8. Insert a piece of stiff wire in end of oil jet tube
and check that non-return valve can be
depressed and closes under spring pressure.
ENGINE
OVERHAUL
75
Camshaft - refit and check end-float
1. Remove all traces of gasket from baffle plate
and cylinder block using suitable gasket
removal spray and a plastic scraper.
2. Lubricate cams, journals and bearings with
engine oil.
3. Ensure thrust plate bolt holes in cylinder block
are clean and dry.
4. Carefully insert camshaft into cylinder block
taking care not to drop end of camshaft on to
bearings.
5. Fit a new thrust plate, fit bolts and tighten to 9
Nm.
6. Temporarily fit camshaft timing gear, fit and
tighten bolt sufficiently to pull gear fully on to
camshaft.
7. Attach a magnetic base DTI to front of cylinder
block with stylus of gauge contacting machined
face of gear adjacent to gear teeth.
8. Push camshaft fully rearwards and zero gauge.
9. Pull camshaft fully forwards and check that
end-float is between 0.1 and 1.2 mm.
10. If end-float exceeds 0.2 mm with new thrust
plate fitted, camshaft must be replaced.
11. Remove DTI and timing gear.
12. Fit oil jet tube and tighten to 17 Nm.
13. Lubricate components of each cam follower
with engine oil.
14. Lubricate cam follower bores with engine oil.
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