300 TDi - Landroverweb
300 TDiENGINEOVERHAULMANUALThis engine is fitted to the following Models from1995 onwards:DiscoveryDefenderRange Rover ClassicPublication Part No. LRL 0070ENGPublished by Rover Technical Communication 1997 Rover Group Limited
INTRODUCTIONINTRODUCTIONReferencesHow to use this manualWith the engine and gearbox assembly removed,the crankshaft pulley end of the engine is referred toas the front.To assist in the use of this manual the section title isgiven at the top and the relevant sub-section is givenat the bottom each page.This manual contains procedures for overhaul of theengine. For all other information regardingadjustments, 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 andData, Torque & Tools.Operations covered in this manual do not includereference to testing the vehicle after repair. It isessential that work is inspected and tested aftercompletion and if necessary a road test of thevehicle is carried out particularly where safetyrelated items are concernedDimensionsThe dimensions quoted are to design engineeringspecification with Service limits where applicable.To assist filing of revised information, eachsub-section is numbered from page 1.Individual items are to be overhauled in thesequence in which they appear in this Manual. Itemsnumbered in the illustrations are referred to in thetext.Overhaul operations include reference to ServiceTool numbers and the associated illustration depictsthe tool. Where usage is not obvious the tool isshown in use. Operations also include reference towear limits, relevant data, torque figures, specialistinformation and useful assembly details.WARNINGS, CAUTIONS and Notes have thefollowing meanings:WARNING: Procedures which must befollowed precisely to avoid the possibilityof injury.CAUTION: Calls attention to procedureswhich must be followed to avoid damageto components.NOTE: Gives helpful information.INTRODUCTION1
INTRODUCTIONREPAIRS AND REPLACEMENTSSPECIFICATIONWhen replacement parts are required it is essentialthat only Land Rover recommended parts are used.Land Rover are constantly seeking to improve thespecification, design and production of their vehiclesand alterations take place accordingly. While everyeffort has been made to ensure the accuracy of thisManual, it should not be regarded as an infallibleguide to current specifications of any particularcomponent or vehicle.Attention is particularly drawn to the following pointsconcerning repairs and the fitting of replacementparts and accessories.Safety features and corrosion prevention treatmentsembodied in the car may be impaired if other thanLand Rover recommended parts are fitted. In certainterritories, legislation prohibits the fitting of parts notto the manufacturer’s specification.Torque wrench setting figures given in this Manualmust be used. Locking devices, where specified,must be fitted. If the efficiency of a locking device isimpaired during removal it must be renewed.The terms of the vehicle Warranty may beinvalidated by the fitting of other than Land Roverrecommended parts. All Land Rover recommendedparts have the full backing of the vehicle Warranty.Land Rover Dealers are obliged to supply only LandRover recommended parts.2INTRODUCTIONThis Manual does not constitute an offer for sale ofany particular component or vehicle. Land RoverDealers are not agents of the Company and have noauthority to bind the manufacturer by any expressedor implied undertaking or representation.
ENGINEThis page is intentionally left blankDESCRIPTION AND OPERATION1
ENGINE2DESCRIPTION AND OPERATION
ENGINECYLINDER BLOCK, PISTONS AND 18.19.Top compression ring2nd compression ringOil control ringPistonGudgeon pin circlipsGudgeon pinConnecting rodBrake servo vacuum pump gasketCore plugConnecting rod boltBig-end bearing shellPush rodCam follower slideRollerCam follower guideGuide retaining boltDipstickDipstick tubeDipstick tube 5.36.37.38.CamshaftOil jet tubeDrive pinCamshaft thrust plateCamshaft bearingsMain bearing shellBaffle plateCore plugsOil pressure switchThermostatic valve assemblyOil filter headFuel lift pumpFuel lift pump gasketsSpacer - if fittedBrake servo vacuum pumpCrankcase breather pipeOil filter head gasketBaffle plate gasketOil filter elementDESCRIPTION AND OPERATION3
ENGINE4DESCRIPTION AND OPERATION
ENGINECRANKSHAFT, SUMP AND OIL ff keyMain bearing shellMain bearing cap - frontMain bearing cap bolt’O’ ring - oil pick-up pipeOil pick-up pipe and strainerSump boltOil drain pipeSumpGasket - oil drain pipeMain bearing cap - rearRear main bearing cap oil seal14.15.16.17.18.19.20.21.22.23.24.25.Crankshaft thrust washersMain bearing cap - centreBig-end bearing capBig-end bearing cap nutBig-end bearing shellOil jet tube banjo boltOil jet tubeOil pumpTiming belt rear coverPlugOil pressure relief valve springOil pressure relief valve plungerDESCRIPTION AND OPERATION5
ENGINE6DESCRIPTION AND OPERATION
ENGINEROCKER SHAFT AND COVER1.2.3.4.5.6.7.8.9.Rocker cover flange nutsSealing washerOil filler capRocker coverRocker cover gasketRocker shaftRocker shaft pedestalFlange boltWasher10.11.12.13.14.15.16.17.18.Rocker arm bushAdjusting screwLocknutRocker armSpacerPedestal studNutCrankcase breather cyclone unit’O’ ringDESCRIPTION AND OPERATION7
ENGINE8DESCRIPTION AND OPERATION
ENGINECYLINDER HEAD1.2.3.4.5.6.7.8.9.10.11.12.13.14.Valve capColletsValve spring cupValve springValve spring seatValve stem sealValve guideExhaust valve seatExhaust valveInlet valve seatInlet valveCylinder head bolt - M12 - longCylinder head bolt - M12 - shortCylinder head bolt - M1015.16.17.18.19.20.21.22.23.24.25.Heater hose adaptorEngine lifting bracketsCore plugsCylinder head gasketThermostat housing gasketCoolant filler plugThermostat housingThermostatCoolant outlet elbowCoolant temperature sensorSealing washerDESCRIPTION AND OPERATION9
ENGINE10DESCRIPTION AND OPERATION
ENGINETIMING BELT REAR COVER AND GEARS1.2.3.4.5.6.7.8.9.10.Camshaft oil sealGasketCrankshaft front oil sealTiming belt rear coverInjection pump drive gearHub plateNut - injection pump hubBolt - injection pump hub plateCamshaft drive gearWasher - camshaft drive gear11.12.13.14.15.16.17.Bolt - camshaft drive gearIdler pulleyRetaining nutCrankshaft gearBolt - timing belt tensioner pulleySpacer - timing belt tensioner pulley boltTiming belt tensioner pulley and tensionerbracket18. Flanged spacer - idler pulley19. ’O’ ringDESCRIPTION AND OPERATION11
ENGINE12DESCRIPTION AND OPERATION
ENGINETIMING BELT AND FRONT COVER1.2.3.4.5.Timing beltGasketAccess plateBolt - access plateTiming belt front cover6.7.8.9.10.Bolts - timing belt front coverWading plugOil sealCrankshaft pulleyPulley boltDESCRIPTION AND OPERATION13
ENGINE14DESCRIPTION AND OPERATION
ENGINEOPERATIONThe 300 TDi is a 4 cylinder, water cooled,turbocharged diesel engine with a capacity of 2.5litres.The cast iron cylinder block is integral with thecrankcase and incorporates direct bored cylinders.The crankshaft is carried in 5 main bearings,end-float being controlled by thrust washers whichare positioned on both sides of the centre mainbearing.The flywheel/drive plate housing is an aluminiumalloy casting secured to the rear of the cylinderblock, it also forms the mounting for the startermotor. A plugged aperture in the housing allowsaccess for the insertion of the timing pin.The aluminium alloy cylinder head carries aconventional rocker shaft and rockers, operating 2valves per cylinder via camshaft followers and pushrods from a single camshaft, supported in thecylinder block by 4 bearings and driven by a gearand toothed belt from the crankshaft. A lobe formedbetween the 2 inner bearing journals provides drivefor the fuel lift pump and another lobe, between the 2drive end journals provides drive for the brake servopump. Camshaft end-float is controlled by a thrustplate bolted to the cylinder block.Graphite coated, aluminium alloy pistons are fittedwith 2 compression and an oil control ring and aresecured to the connecting rods by semi-floatinggudgeon pins which are an interference fit in thesmall end bush. A swirl chamber is incorporated inthe piston crown to facilitate combustion.The timing case consists of cast aluminium alloyfront and rear covers which house the oil pump,crankshaft and camshaft front oil seals and whichalso carry the fuel injection pump and drive belt idlerpulley. Housed within the timing case housing is thecrankshaft gear which provides drive for thecamshaft and fuel injection pump gears via a rubbertoothed belt.DESCRIPTION AND OPERATION15
ENGINE16DESCRIPTION AND OPERATION
ENGINELubricationThe engine lubrication system is of the wet sumptype, oil pressure being provided by the rotor type oilpump (1) driven directly by the crankshaft.Oil is drawn from the sump (2) through the strainer(3), suction pipe (4) and passes through internaldrillings in the cylinder block to an external, full flowfilter (5). Further drillings feed oil to the cylinderblock main oil gallery (6) which, in turn, supplies thecrankshaft main bearings (7). Cross drillings in thecrankshaft carry oil to the connecting rod big-endbearings (8). The camshaft bearings (9) are suppliedwith oil from the main oil gallery.An internal oilway from the camshaft front bearingconnects the cylinder block to the cylinder head andfeeds oil to the rocker shaft assembly (10),lubricating the valves and springs.The pistons, gudgeon pins and small end bushesare lubricated and cooled by oil jets (11) which aresupplied from the main oil gallery via relief valveswhich allow the oil to flow at a pre-determinedpressure.Oil pressure is controlled by a pressure relief valve(12) incorporated in the timing case housingtogether with the oil pump. The valve allows excessoil to be recirculated back into the oil feed gallery.The rotor type oil pump is driven by 2 flats machinedon the front of the crankshaft.Oil cooling is maintained by an oil cooler which isintegral with the radiator and linked to adaptors onthe oil filter head by pre-formed feed and returnhoses. A thermostatic valve in the filter head allowsoil to flow to the cooler when it reaches apre-determined temperature.DESCRIPTION AND OPERATION17
ENGINECrankcase ventilation systemA breather cyclone unit (1), fitted to the right handside of the rocker cover controls the rate at which airis purged from the sump, via a hose (2) from thecamshaft side cover to the rocker cover and extracts18DESCRIPTION AND OPERATIONoil from the gaseous atmosphere. The oil then drainsback to the sump through a hose and flanged pipeconnection (3). The residues are drained-off fromthe top of the cyclone breather and pass through ahose (4) into the engine via the turbocharger wherethey are burned in the combustion chamber.
ENGINETIMING BELT, TENSIONER AND GEARSTiming belt - remove4. Position tool LRT-12-049 and thrust button,part of tool LRT-12-031 to crankshaft pulley,remove pulley, recover Woodruff key.1. Position tool LRT-12-080 to crankshaft pulley,retain with 4 bolts.2. Restrain crankshaft using tool LRT-12-080and remove crankshaft pulley flange head bolt.NOTE: Bolt and washer fitted to earlyengines.3. Remove tool LRT-12-080 .5. Using sequence shown, progressively slackenthen remove 14 bolts securing timing belt frontcover.OVERHAUL1
ENGINEAutomatic gearbox12. Rotate crankshaft clockwise using crankshaftpulley bolt until tool LRT-12-044 can beinserted through hole in engine plate and intoslot in drive plate.6. Remove timing belt front cover.7. Remove and discard gasket.8. Remove and discard crankshaft front oil sealfrom timing belt front cover.9. Temporarily fit crankshaft pulley bolt tocrankshaft.Manual gearbox10. Remove plug from bottom of flywheel housing.11. Rotate crankshaft clockwise using crankshaftpulley bolt until tool LRT-12-044 can belocated in slot in flywheel.CAUTION: Do not rotate crankshaftanti-clockwise and do not use camshaft orfuel injection pump gear bolts to rotatecrankshaft.2OVERHAULCAUTION: Do not rotate crankshaftanti-clockwise and do not use camshaft orfuel injection pump gear bolts to rotatecrankshaft.
ENGINEAll engines13. Check that timing mark on camshaft pulley isaligned with mark on timing belt rear cover andthe crankshaft Woodruff key is aligned with thearrow cast on the rear cover.14. Remove crankshaft pulley bolt.15. Insert timing pin LRT-12-045 into fuel injectionpump gear hub plate and injection pump hub.18. Slacken but do not remove bolt securing timingbelt tensioner pulley, move pulley until tensionis removed from belt.19. Remove nut and washer securing idler pulley.20. Release idler pulley from timing belt, removepulley.21. Release timing belt from gears, discard belt.16. Slacken but do not remove centre bolt securingcamshaft drive gear to camshaft.17. If timing belt is to be refitted, mark direction ofrotation on outside surface of belt with chalk orsimilar soft material.OVERHAUL3
ENGINETiming belt tensioner and timing gears - remove5. Remove centre bolt and washer securingcamshaft timing gear, remove gear and hubplate as an assembly.1. Remove crankshaft gear using toolsLRT-12-031 and LRT-12-078, recoverWoodruff key from crankshaft.2. Remove and discard ’O’ ring.3. Remove bolt and slotted washer securingtiming belt tensioner pulley, remove pulleytogether with tensioner bracket.4. Recover flanged spacer from idler pulley stud.4OVERHAULNOTE: Later engines are fitted with aflange head bolt.CAUTION: Do not remove 3 bolts securinghub plate to gear.
ENGINEInspecting components1. Check timing gear teeth for burrs.2. Remove all traces of gasket from timing beltfront and rear covers using suitable gasketremoval spray and a plastic scraper.6. Remove 3 bolts securing fuel injection pumpgear and hub plate to pump hub.CAUTION: Do not remove nut securinghub to fuel injection pump.7. Remove timing pin LRT-12-045.8. Remove fuel injection pump gear and hubplate.OVERHAUL5
ENGINETiming belt tensioner and gears - refit1. Smear a new ’O’ ring with engine oil and fit tocrankshaft.2. Fit Woodruff key in slot in crankshaft.3. Fit crankshaft gear on to crankshaft and usinga soft mallet, tap gear fully home.5. Position fuel injection pump gear and hub plateto fuel injection pump hub ensuring that cut-outin hub plate is aligned with timing pin hole inpump hub.6. Fit 3 bolts, position slots in gear mid-way underbolt heads, lightly tighten bolts.CAUTION: Do not fit bolts throughelongated slots in hub plate. Ensure geardoes not move as bolts are tightened.7. Insert timing pin LRT-12-045 in hub plate andinjection pump hub. If timing pin cannot beinserted, slacken bolts and rotate gear until pincan be fitted, lightly tighten bolts.4. Position camshaft timing gear and hub plate tocamshaft, fit bolt and washer, finger tightenbolt. Do not tighten bolt at this stage.NOTE: Later engines are fitted with aflange head bolt.6OVERHAUL
ENGINENOTE: Flywheel illustrated8. Position flanged spacer on idler pulley stud.9. Fit timing belt tensioner pulley and bracketensuring that hole in tensioner bracket islocated on flanged spacer.10. Fit slotted washer with the slot vertical and fitbolt, finger tight.11. Temporarily fit crankshaft pulley bolt tocrankshaft.12. Manual gearbox: Rotate crankshaft clockwiseusing crankshaft pulley bolt until toolLRT-12-044 can be inserted in slot in flywheel.13. Automatic gearbox: Rotate crankshaftclockwise using crankshaft pulley bolt until toolLRT-12-044 can be inserted in slot in driveplate.14. Check that crankshaft Woodruff key is alignedwith arrow on timing belt rear cover.15. If necessary, rotate camshaft timing gear usingthe centre bolt until timing mark on gear isaligned with timing mark on timing belt rearcover.16. Remove crankshaft pulley bolt.OVERHAUL7
ENGINETiming belt - refit and adjust tensionAdjust tensionRefit1. Ensure tools LRT-12-044 and LRT-12-045are still fitted.1. Using the fingers only, fit a new timing belt totiming gears keeping slack portion of belt onidler pulley side of belt. If necessary, rotate fuelinjection pump gear anti-clockwise to aligngear teeth with those of timing belt.CAUTION: If original timing belt is to berefitted, ensure direction of rotation markis 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 ontiming gears.5. Check that tensioner pulley bolt is finger tight.6. Temporarily fit crankshaft pulley bolt tocrankshaft.8OVERHAUL2. Position a dial type torque wrench and suitableextension to hole in tensioner bracket keepingthe torque wrench positioned vertically.3. Tension timing belt to :Used belt - 12 NmNew belt - 15 Nm4. Keeping timing belt at the correct tension,tighten tensioner bolt to 45 Nm.
ENGINE16. Support timing belt front cover on suitableblocks of wood.17. Smear a new crankshaft oil seal with engineoil.18. Using tool LRT-12-077, fit oil seal from insideface of front cover.5. Check that timing pin LRT-12-045 movesfreely in and out of injection pump hub, if pindoes not move freely, slacken 3 bolts, movegear slightly and re-check.6. When timing pin moves freely, tighten 3 boltsto 25 Nm.7. Remove timing pin LRT-12-045 andflywheel/drive plate locking tool LRT-12-044.8. Rotate crankshaft twice in a clockwise directionusing crankshaft pulley bolt until flywheel/driveplate locking tool LRT-12-044 can be refitted.9. Slacken timing belt tensioner securing bolt andre-tension timing belt.10. Tighten tensioner bolt to 45 Nm.11. Fit timing pin LRT-12-045 into fuel injectionpump gear hub plate and pump hub. If timingpin cannot be inserted, slacken injection pumpgear bolts, rotate pump shaft using shaft nutuntil pin slides easily into pump hub, Tightenbolts to 25 Nm.12. Tighten camshaft gear bolt to 80 Nm.13. Remove timing pin and flywheel/drive platelocking tools.14. Fit plug to flywheel housing, tighten to 12 Nm.15. Remove crankshaft pulley bolt.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 positionsshown.OVERHAUL9
ENGINE22. Tighten bolts in sequence shown to 25 Nm.23. Lightly oil crankshaft spigot, fit Woodruff keyand 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 80Nm,then further 90. 27. Remove tool LRT-12-080.10OVERHAUL
ENGINEROCKER SHAFTRemove5. Remove 3 flange nuts securing rocker cover,recover sealing washers.6. Remove rocker cover, remove and discardgasket.1. Disconnect breather hoses from crankcasebreather cyclone unit.2. Remove bolt securing cyclone unit to rockercover.3. Remove cyclone unit, remove and discard ’O’ring.4. Disconnect breather hoses from cylinder blockand rocker cover.7. Slacken locknut on each tappet adjustingscrew, slacken adjusting screws until they areclear of push rods.8. Working from the centre outwards,progressively slacken then remove 3 nuts and2 bolts securing rocker shaft pedestals tocylinder head.CAUTION: Insert a slave bolt intopedestals 1 and 5 to prevent componentssliding off shaft.9. Remove rocker shaft assembly.OVERHAUL11
ENGINERocker shaft - dismantling1. Suitably identify each component to its fittedposition.10. Withdraw push rods.11. Remove valve caps.CAUTION: Keep push rods and valve capsin their fitted order.2. Remove locknut and tappet adjusting screwfrom each rocker.3. Remove slave bolt and pedestal from end ofrocker shaft.4. Remove washer, rocker arm and spacerfollowed by second rocker arm, spacer andpedestal.5. Repeat above procedures until all componentsare removed.12OVERHAUL
ENGINEInspecting components1. Measure and reco
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 1 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 .
TDI 2.5L 140/150/165 TDI 150‑5/TDI 150‑5 D/TDI 165‑5 EXVWM004 R4 TD; TDI 1.9L 75 TDI 75‑4 EXVWM006 TDI 3.0L 230/260 TDI 230‑6/TDI 260‑6 EXVWM007 TDI 4.2L 285/350 TDI 285‑8/TDI 350‑8 EXVWM008 Essential requirements Standards Other normative document/ method Technical file Please specify in more detail (* mandatory standard)
MONTERINGSANVISNING ASENNUSOHJEET ASSEMBLY INSTRUCTIONS EINBAUHINWEISE TYP RE 480 EFFEKT: 550W / 230V 13.09.27 IP46 M5S 480 Motortyp Moottorityyppi Engine model AUDI A3 1.9 TDi 2001- ALH A3 1.9 TDI 2001- ATD SKODA Fabia 1.9 TDi ATD Octavia 1.9 TDi 4x4 ATD Roomster 1.4 TDi 2006- BNM SEAT Leon 1.9 TDi 2000- ALH Toledo 1.9 TDi 2002- ALH .
2.0L TDI (CBEA) All All All Golf, Jetta, Jetta SportWagen 2010-2013 2.0L TDI (CJAA) All All All Passat 2012-2013 2.0L TDI (CKRA) All All All Touareg 2009-2010 3.0L TDI (CKRA) All All All Touareg 2011-2013 3.0L TDI (CNRB) All All All Beetle 2013 2.0L TDI (CJAA) All All All Condition
TDI by BASF is an 80:20 mixture of the 2,4- and 2,6-TDI isomers assaying 99.5% TDI minimum, as shown in Figure 3. TDI is produced in several grades that diff
2017 Audi Maintenance Schedule - All Models MY 2017 Maintenance Intervals - USA . (S3, A4 TDI, A5 TDI, A6 TDI, A8 TDI, A8 3.0T, A8 4.0T, Q5 TDI, TTS) 1) The S8 4.0L V8 TFSI engine is not included in this interval. It must be performed first at 60,000 miles and thereafter every 60,000 miles.
The TDI-BH includes a rechargeable NiMH battery pack as the primary power source, and a standard alkaline battery pack as a backup. Fully charged, they supply a nominal 12 volts (the NiMH may be slightly less) and will power the TDI-BH for about 4-6 hours. The TDI will operate until the batteries drop
VW TDI engine is on the order of 0.25 second, which is not noticeable to the driver. Electronically controlled emission control systems, including EGR (exhaust gas recirculation), reduce emissions of nitrogen oxides (NOx). Previous VW diesels did not include this function because the mechanical controls were not capable of providing adequate .
Application of Silicon Carbide in Abrasive Water Jet Machining Ahsan Ali Khan and Mohammad Yeakub Ali International Islamic University Malaysia Malaysia 1. Introduction Silicon carbide (SiC) is a compound consisting of silicon and carbon. It is also known as carborundum. SiC is used as an abrasive ma terial after it was mass produced in 1893. The credit of mass production of SiC goes to Ed .
