300Tdi Engine Overhaul

300 TDi ENGINE

OVERHAUL MANUAL
This engine is fitted to the following Models from 1995 onwards:

Discovery Defender Range Rover Classic

Publication Part No. LRL 0070ENG Published by Rover Technical Communication © 1997 Rover Group Limited

INTRODUCTION
INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevantsub-section is given at the bottom each page. This manual contains procedures for overhaul of the engine. For all other information regarding adjustments, removal of oil seals and engine, consult the Repair Manual for the model concerned. This manual is divided into 3 sections: Description and Operation, Overhaul and Data, Torque & Tools. To assist filing of revised information, each sub-section isnumbered from page 1. Individual items are to be overhauled in the sequence in which they appear in this Manual. Items numbered in the illustrations are referred to in the text. Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool. Where usage is not obvious the tool is shown in use. Operations also include reference to wear limits, relevantdata, torque figures, specialist information and useful assembly details. WARNINGS, CAUTIONS and Notes have the following meanings: WARNING: Procedures which must be followed precisely to avoid the possibility of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. NOTE: Gives helpful information.
     

References With the engine and gearboxassembly removed, the crankshaft pulley end of the engine is referred to as the front. Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned Dimensions The dimensions quoted are todesign engineering specification with Service limits where applicable.

INTRODUCTION

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INTRODUCTION
REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Land Rover recommended parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories. Safety features and corrosionprevention treatments embodied in the car may be impaired if other than Land Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer’s specification. Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal itmust be renewed. The terms of the vehicle Warranty may be invalidated by the fitting of other than Land Rover recommended parts. All Land Rover recommended parts have the full backing of the vehicle Warranty. Land Rover Dealers are obliged to supply only Land Rover recommended parts. SPECIFICATION Land Rover are constantly seeking to improve the specification, design and production of their vehiclesand alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular component or vehicle. This Manual does not constitute an offer for sale of any particular component or vehicle. Land Rover Dealers are not agents of the Company and have no authority to bind themanufacturer by any expressed or implied undertaking or representation.

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INTRODUCTION

ENGINE

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DESCRIPTION AND OPERATION

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ENGINE

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DESCRIPTION AND OPERATION

ENGINE
CYLINDER BLOCK, PISTONS AND CAMSHAFT

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Top compression ring 2nd compression ring Oil...