An essential reference for any 300 Tdi engine rebuild. Includes complete overhaul information for the R380 manual gearbox and LT230T transfer gearbox. Very useful resource for updating or converting to a 300 Tdi engine..

Covers 300 Tdi Diesel as fitted from 1995 onwards to
• Discovery
• Defender
• Range Rover Classic

• Engine
  • DESCRIPTION AND OPERATION
    • CYLINDER BLOCK, PISTONS AND CAMSHAFT
    • CRANKSHAFT, SUMP AND OIL PUMP
    • ROCKER SHAFT AND COVER
    • CYLINDER HEAD
    • TIMING BELT REAR COVER AND GEARS
    • TIMING BELT AND FRONT COVER
    • OPERATION
  • OVERHAUL
    • TIMING BELT, TENSIONER AND GEARS
      remove | tensioner and timing gears- remove | tensioner and gears - refit | Timing belt - refit and adjust tension
    • ROCKER SHAFT
      Rocker shaft - dismantling | Rocker arm bushes - replace | Rocker shaft - assembling | Rocker shaft- refit
    • VALVE CLEARANCES - ADJUST
    • CYLINDER HEAD
      Valves and springs - remove | Cylinder head - inspection | Valve springs - inspection | Valves and guides - inspection | Valve guides - renew | Valve seat inserts - refacing | Valve seat inserts - renew | Lapping-in valves | Valve head stand down - checking | Valves and springs - refit | Cylinder head gasket selection | Cylinder head - refit
    • TIMING BELT REAR COVER AND OIL PUMP
      Timing belt rear cover - remove | Oil pump and oil pressure relief valve - remove | Oil pump and oil pressure relief valve - refit | Timing belt rear cover - refit
    • OIL FILTER HEAD
      Thermostatic valve - remove | Thermostatic valve - refit | Oil filter head - refit
    • FUEL INJECTION PUMP
    • FUEL LIFT PUMP
    • FUEL INJECTORS
    • GLOWPLUGS
    • BRAKE SERVO VACUUM PUMP
    • SUMP, OIL PICK-UP AND DRAIN PIPES
      Sump - remove | Oil pick-up and drain pipes - remove | Oil pick-up and drain pipes - refit | Sump - refit
    • FLYWHEEL AND STARTER RING GEAR
      Flywheel - remove | Starter ring gear - replace | Flywheel - refit
    • DRIVE PLATE
      Dnve plate - refit
    • FLYWHEEL/DRIVE PLATE HOUSING
    • CRANKSHAFT, CAMSHAFT, PISTONS AND CYLINDER BLOCK
      Crankshaft rear oil seal - remove | Big-end bearings - remove | Crankshaft and main bearings - remove | Crankshaft - inspection | Crankshaft - regrinding | Main bearing caps and saddles - inspection | Main bearing clearance - checking Crankshaft end-float - checking | Big-end bearing clearance - checking | Crankshaft, main and big-end bearings - refit | Crankshaft rear oil seal - refit | Pistons and connecting rods - remove | Pistons and connecting rods - inspection | Piston rings - checking | Oil jet tubes - inspection | Pistons and connecting rods - refit | Oil jet tubes - refit | Camshaft - remove | Camshaft, bearings and cam followers - inspection | Camshaft - refit and check end-float | Cylinder block - inspection
  • DATA, TORQUE & TOOLS
    • ENGINE DATA
    • TORQUE FIGURES
    • TOOL NUMBERS
• Manual Gearbox
  • DESCRIPTION AND OPERATION
    • DESCRIPTION
    • GEARBOX COMPONENTS - GEARS AND SHAFTS
    • GEARBOX CASINGS
    • GEAR CHANGE HOUSING - TYPE A GEARBOX
    • GEAR CHANGE HOUSING - TYPE B GEARBOX
    • REMOTE GEAR CHANGE HOUSING - TYPE C GEARBOX
    • TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX
  • OVERHAUL
    • GEAR BOX DISMANTLE
      Clutch housing - Type A gearbox - Remove | Clutch housing - Type B gearbox - Remove | Clutch housing - Type C gearbox - Remove | Clutch housing - Type D gearbox - Remove | Gear change/selector housings - Type A gearbox - Remove | Remote housing - Type A gearbox - Remove | Gear change/selector housings - Type B gearbox - Remove | Selector quadrant - Type A gearbox - Remove | Gear change lever yoke - Type B gearbox - Remove | Remote gear change - Type C gearbox - Remove | Remote gear change - Type D gearbox - Remove | Gear change lever yoke - Type D gearbox - Remove | Extension housing - Types A and B gearbox - Remove | Extension housing - Type C gearbox - Remove | Extension housing - Type D gearbox - Remove | 5th and Reverse gear - Remove | Mainshaft and layshaft - Remove | Mainshaft - Dismantle | Gearbox casing | Front Cover - Dismantle | Centre plate - Dismantle | Extension housing - Types A and B gearbox - Overhaul | Gear change/selector housings - Overhaul | Synch romesh assemblies - Overhaul | Checking baulk ring clearances | Input shaft - Overhaul | Mainshaft - Inspection | Layshaft - Overhaul | Mainshaft - Reassembly | Reverse idle gear - Reassembly | Selectors - Inspection
    • GEARBOX REASSEMBLE
      Mainshaft and layshaft end float | Shimming | Assembling mainshaft and layshaft to centre plate | Reverse and 5th gear - Reassembly | Extension housing - Type A and B Gearbox - Refit | Extension housing - Type C gearbox - Refit | Extension housing - Type D gearbox - Refit | Selector quadrant - Type A gearbox - Refit | Gear change lever yoke - Type B gearbox - Refit | Gear change lever yoke - Type D gearboxes - Refit | Remote housing - Type A gearbox - Refit | Transfer box selector housing - Type A gearbox - Refit | Gear change housing - Type A gearbox - Refit | Transfer box selector housing - Type B gearbox - Refit | Gear change housing - Type B gearbox - Refit | Remote gear change - Type C gearbox - Refit | Remote gear change - Type D gearbox - Refit 5th gear stop screw adjustment - Type A gearbox | Bias spring adjustment - Type A gearbox | Bias spring adjustment - Type B gearbox | Bias spring adjustment - Type C gearbox | Clutch housing - Type A gearbox - Refit Clutch housing - Type B gearbox - Refit | Clutch housing - Type C gearbox - Refit | Adaptor housing - Type D gearbox - Refit
• Transfer Box
  • DESCRIPTION AND OPERATION
    • FRONT OUTPUT HOUSING COMPONENTS
    • DIFFERENTIAL COMPONENTS
    • MAIN CASING COMPONENTS
    • REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS
    • OPERATION
  • OVERHAUL
    • TRANSFER BOX DISMANTLING
    • COMPONENT DISMANTLING
      High/low cross shaft housing | Front output housing | Rear output housing | Main casing | Mainshaft input gear bearing housing | Intermediate gears | Mainshaft input gear assembly | Differential lock selector | Differential
    • INSPECTING COMPONENTS
      Intermediate gears and shaft | Mainshaft input gear | High/low cross shaft and housing | Front output housing and differential lock selector | Rear output housing | Main casing | Mainshaft input gear bearing housing | High/low selector fork and shaft | Differential
    • COMPONENT ASSEMBLING
      Main casing | Mainshaft input gear bearing housing | Mainshaft input gear assembly | Intermediate gears | Rear output housing | Front output housing | High/low cross shaft housing | Differential lock selector
    • TRANSFER BOX ASSEMBLING
      Mainshaft input gear bearing pre-load | Differential load to turn - bearing pre-load | Front output housing | Rear output housing | Intermediate gears | Intermediate gear load to turn - bearing pre-load | Bottom cover | High/low selector shaft detent | Differential lock warning lamp switch - adjust | Transmission brake