engine LAND ROVER DISCOVERY 1995 Service Repair Manual

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
Ó1997 Rover Group Limited

INTRODUCTION
INTRODUCTION1
INTRODUCTION
How to use this manual
To assist in the use of this manual the section title is
given at the top and the relevant sub-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 is numbered 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, relevant data, 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 gearbox assembly 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 to design engineering
specification with Service limits where applicable.

ENGINE
DESCRIPTION AND OPERATION1
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ENGINE
2
DESCRIPTION AND OPERATION

ENGINE
DESCRIPTION AND OPERATION3
CYLINDER BLOCK, PISTONS AND CAMSHAFT
1.Top compression ring
2.2nd compression ring
3.Oil control ring
4.Piston
5.Gudgeon pin circlips
6.Gudgeon pin
7.Connecting rod
8.Brake servo vacuum pump gasket
9.Core plug
10.Connecting rod bolt
11.Big-end bearing shell
12.Push rod
13.Cam follower slide
14.Roller
15.Cam follower guide
16.Guide retaining bolt
17.Dipstick
18.Dipstick tube
19.Dipstick tube bolt20.Camshaft
21.Oil jet tube
22.Drive pin
23.Camshaft thrust plate
24.Camshaft bearings
25.Main bearing shell
26.Baffle plate
27.Core plugs
28.Oil pressure switch
29.Thermostatic valve assembly
30.Oil filter head
31.Fuel lift pump
32.Fuel lift pump gaskets
33.Spacer - if fitted
34.Brake servo vacuum pump
35.Crankcase breather pipe
36.Oil filter head gasket
37.Baffle plate gasket
38.Oil filter element

ENGINE
4
DESCRIPTION AND OPERATION

ENGINE
DESCRIPTION AND OPERATION5
CRANKSHAFT, SUMP AND OIL PUMP
1.Crankshaft
2.Woodruff key
3.Main bearing shell
4.Main bearing cap - front
5.Main bearing cap bolt
6.'O' ring - oil pick-up pipe
7.Oil pick-up pipe and strainer
8.Sump bolt
9.Oil drain pipe
10.Sump
11.Gasket - oil drain pipe
12.Main bearing cap - rear
13.Rear main bearing cap oil seal14.Crankshaft thrust washers
15.Main bearing cap - centre
16.Big-end bearing cap
17.Big-end bearing cap nut
18.Big-end bearing shell
19.Oil jet tube banjo bolt
20.Oil jet tube
21.Oil pump
22.Timing belt rear cover
23.Plug
24.Oil pressure relief valve spring
25.Oil pressure relief valve plunger

ENGINE
6
DESCRIPTION AND OPERATION

ENGINE
DESCRIPTION AND OPERATION7
ROCKER SHAFT AND COVER
1.Rocker cover flange nuts
2.Sealing washer
3.Oil filler cap
4.Rocker cover
5.Rocker cover gasket
6.Rocker shaft
7.Rocker shaft pedestal
8.Flange bolt
9.Washer10.Rocker arm bush
11.Adjusting screw
12.Locknut
13.Rocker arm
14.Spacer
15.Pedestal stud
16.Nut
17.Crankcase breather cyclone unit
18.'O' ring

ENGINE
8
DESCRIPTION AND OPERATION