Thread: 300tdi Injection Pump retaining tool - LRT-12-045

I needed to remove the 300tdi injection pump today. To retain the IP pulley and timing belt tension inside the timing case whilst removing the IP the rover manual calls for LandRover Special Tool LRT-12-045.

When doing a timing belt replacement you would have used part of this kit to lock the IP at TDC. In place of the flash LR retaining pin you can use a 11/32drill bit.

Now to make the LRT-12-045 plate.
To make things easy I used the IP to pump pulley retaining plate (held on with 3 bolts accessed through the front cover hole) as a template. LRT-12-045 needs to have holes made in three places. The large U-shaped hole which is where the 11/32 drill bit slides through to lock the IP and the two slotted holes. I used some 100mm by 10mm thick Al flat I had lying around and made the retaining plate 100x100mm.

In the middle of this I copied the template holes and then drilled them out as best as possible. The pictures show the end result-rough but functional.

You will also need two retaining bolts M8 I believe, with the 10mm plate I needed about 35mm of bolt shank to secure the pump pulley.


The manual is pretty clear but Ill add a few points:
-remove viscous fan and shroud
-remove A/C tensioner, My A/C is an airpump so I pulled the whole pump off for better access, not sure how fiddly this job would be with the A/C insitu.
-find TDC, lock flywheel and place 11/32 drill bit through to lock Injection Pump in place.
-remove the IP to pulley retaining plate (3 bolts with 10mm heads)
-the IP pulley has an arrow marked on it, mark the front timing cover case in line with this to give a fix point for pulley at TDC
-slide the LRT-12-045 over the drill bit and align the slotted holes with the threaded holes on the IP pulley, insert and tighten two retaining bolts. These will hold the IP pulley in place and keep tension on the timing belt whilst the IP is removed.
-disconnect all fuel / turbo lines and wiring.
-remove Injection Pump. It is possible to withdraw the pump with a standard sutton 11/32 drill bit still in place.
-do what needs to be done to IP


-Before refitting IP ensure drill bit is locking IP at "TDC" (saves time finding it later)
-carefully align pump up with three locating studs AND the hole through the IP pulley and LRT-12-045
-tighten three nuts onto the IP locating studs (25NM) and then the IP bracket bolts as per manual
-refit all fuel / turbo lines and wiring.
-now carefully remove LRT-12-045 whilst leaving the 11/32 bit in place.
-ensure previous match marks for IP pulley and front casing are aligned.
-bolt up the IP to pulley retaining plate to 25NM
-remove 11/32 bit and flywheel locking pin and rotate crank twice back to TDC, make sure the 11/32 bit slides easily into IP and that the groove in the flywheel align.

Hope it helps someone
Regards
Steve

Wow wow wow!!! This help a lot! Thanks!