Defender 300Tdi (1996+). Manual — part 18
ENGINE
15
REPAIR
FLYWHEEL
Service repair no - 12.53.07
Remove
1. Disconnect battery.
2. Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3. Remove clutch.
See CLUTCH, Repair, Clutch
assembly
4. Fit 2, long, 8 mm bolts into the clutch bolt holes,
as shown, to use as handles when lifting the
flywheel off the crankshaft.
5. Remove fan cowl.
See COOLING SYSTEM,
Repair, Fan cowl
6. Fit crankshaft pulley retainer LRT-12-080 and
secure with 4 bolts, to restrain crankshaft while
removing flywheel retaining bolts.
7. Remove bolts and lift off flywheel.
Refit
NOTE: To prevent excessive flywheel
run-out, ensure that mating faces of
flywheel and crankshaft are clean.
8. Locate flywheel on crankshaft, remove lifting
bolts, and secure flywheel with new patched
retaining bolts, progressively tighten to
147 Nm
(108 lbf/ft).
9. Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114 mm (4.50 in) from the centre.
10. Turn flywheel and check that run-out does not
exceed 0,07 mm (0.003 in).
11. Should run-out be excessive, remove flywheel
and check again for irregularities on crankshaft
and flywheel mating faces and location dowel.
12. Remove crankshaft pulley retainer.
13. Fit fan cowl.
See COOLING SYSTEM, Repair,
Fan cowl
14. Fit clutch.
See CLUTCH, Repair, Clutch
assembly
15. Fit gearbox.
See MANUAL GEARBOX, Repair,
R380 gearbox
16. Reconnect battery.
12
ENGINE
16
REPAIR
CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing, the complete housing
assembly (1) must be renewed. Housing and seal
assemblies are supplied with their own
former/seal guide (2) already fitted. This former
must not be removed before fitting the assembly
to the engine. If a seal and housing assembly is
received without a former/guide fitted it must be
returned to the supplier. Used formers/guides
must be discarded immediately after use, under
no circumstances should they be reused on other
assemblies.
NOTE: A different rear oil seal housing,
with integral ’O’ ring seal and gasket, was
fitted on earlier engines. They must be
replaced with the current housing and gasket (3)
shown below.
1. Disconnect battery.
2. Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3. Remove clutch.
See CLUTCH, Repair, Clutch
assembly
4. Remove flywheel.
See Flywheel
5. Remove 5 bolts and withdraw seal housing,
complete with gasket.
Refit
NOTE: The raised side of groove at the
bottom of seal housing gasket must be
fitted to cylinder block face.
6. Insert slave studs to locate seal housing gasket.
7. Position new gasket over slave studs and
crankshaft flange onto cylinder block.
8. Fit new seal housing assembly, with
former/guide in-situ, over crankshaft flange. This
action will eject former/guide.
9. Secure assembly to cylinder block, removing
slave studs individually and inserting bolts.
Tighten to
25 Nm (18 lbf/ft).
10. Refit flywheel.
See Flywheel
ENGINE
17
REPAIR
11. Refit clutch.
See CLUTCH, Repair, Clutch
assembly
12. Refit gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
13. Reconnect battery.
CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
Remove
1. Disconnect battery.
2. Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3. Remove clutch.
See CLUTCH, Repair, Clutch
assembly
4. Remove flywheel.
See Flywheel
5. Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.
Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Refit
1. Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
2. Refit flywheel.
See Flywheel
3. Refit clutch.
See CLUTCH, Repair, Clutch
assembly
4. Refit gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
5. Reconnect battery.
12
ENGINE
18
REPAIR
FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
1. Disconnect battery.
2. Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3. Remove clutch.
See CLUTCH, Repair, Clutch
assembly
4. Remove flywheel.
See Flywheel
5. Remove 3 fixings and withdraw starter motor.
6. Remove 2 bolts from top of flywheel housing.
7. Remove 4 bolts securing bottom of flywheel
housing to engine mounting brackets.
8. Remove inner bolts and lift off flywheel housing.
Refit
9. Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.
10. Apply sealant to flywheel housing mating face on
cylinder block.
11. Fit housing to cylinder block. Tighten retaining
bolts to
45 Nm (33 lbf/ft).
12. Remove surplus sealant from block.
13. Fit starter motor.
14. Fit flywheel.
See Flywheel
15. Fit clutch.
See CLUTCH, Repair, Clutch
assembly
16. Fit gearbox.
See MANUAL GEARBOX, Repair,
R380 gearbox
17. Reconnect battery.
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