Rover 2.25 Liter 4 Cylinder Engine Service manual

Rover Engines
5 — 391
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER
GENERAL SPECIFICATIONS
Displ. Torque (Ft. Compr. Bore Stroke
Year cu ins. ec Carburetor | HP at RPM Lbs. at RPM) Ratio in | mm n_n mm
1971-72) 139.5 2286 1-Bbl. 81@4250 12702500 8.0-1 3.562 | 90.47 3.5 88.9
ENGINE IDENTIFICATION
Engine serial number is stamped on left front of engine.
ENGINE REMOVAL
1) Remove hood, air cleaner, radiator and front floor.
2) Disconnect exhaust pipe at manifold.
3) Disconnect heater hoses, if fitted.
4) Disconnect carburetor linkage at ball joint and choke cable
at carburetor.
5) Remove distributor leads from coil and engine ground
cable.
6) Disconnect fuel inlet pipe at fuel pump.
7) Remove clutch hydraulic line from retaining clips at rear of
engine.
8) Disconnect the following electrical leads:
Starter at solenoid.
Alternator.
Snap connectors next to firewall and retaining clips.
9) Remove speedometer from retaining clip on engine.
10) Disconnect vacuum line at distributor.
11) Remove upper nuts from rubber engine mounts.
12) Attach lifting sling to engine lifting hooks.
13) Remove lower nut from left-hand rubber engine mount.
14) Remove support bracket bolts from right-hand rubber
engine mount.
15) Tension hoist sufficient to withdraw rubber engine
mounts, then lower engine to its original position.
16) Remove bolts attaching bell housing to flywheel housing.
17) Move clutch slave cylinder aside without disconnecting
hydraulic line.
18) Support transmission with a suitable jack or stand.
19) Pull engine forward enough to clear bell housing and
clutch pinion.
20) Litt engine clear of body.
CYLINDER HEAD REMOVAL
1) Remove hood, air cleaner, and battery ground cable.
2) Drain cooling system.
3) Disconnect vacuum line at distributor.
4) Disconnect distributor leads at coil and high tension leads
at spark plugs.
5) Remove spark plugs.
6) Remove fan shroud.
7) Disconnect oil gallery pipe.
8) Disconnect by-pass hose and hose from thermostat hous-
ing.
9) Disconnect carburetor linkage at ball joint and choke
cable at carburetor.
10) Disconnect fuel line at carburetor and release line from
clip on head.
11) Remove heat shield and disconnect exhaust pipe from
manifold.
12) Remove rocker arm cover.
13) Loosen tappet adjusting screws to remove load on rocker
arms.
14) Remove rocker arm support bolts. Do not remove rocker
arm assembly at this point.
15) Invert rocker cover and slide over studs. Secure rocker
arm assembly to cover. Lift off rocker arm assembly and cover
as a unit.
16) Remove push rods and retain them in order for
reassembly.
17) Remove remaining head bolts and lift off head.
NOTE — When reinstalling cylinder head, coat both sides of
head gasket with oil. Position head gasket with lettering
"PETROL" upward.
13
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FRONT — >
1E140
CYLINDER HEAD TIGHTENING SEQUENCE
Copyright (c) 2003 Mitchell Repair Information Company
Rover Engines
5—392
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
VALVES
Engine Head Face Seat Seat Stem Stem Valve
& Valve Diam. Angle | Angle Width Diameter Clearance Lift
2.25 Liter
Int. 1.750-1.755" 30° 30° | uen .3107-.3112" .0013-.001 9" 374"
Exh. 1.375-1.380" 45° 45° |... .3410-.3145" .0023-.0029" ‚388”
VALVE ARRANGEMENT
E-I-I-E-E-1-1-E (front to rear).
VALVE GUIDES
If guides are worn, drive out of cylinder head. Lubricate new
guide and drive into head using a suitable drift.
VALVE STEM OIL SEALS
Fit valve stem seals to valve guide with large diameter toward
valve guide. Stem seal with external projections is fitted to ex-
haust valve guide. Seal with spring is for intake valve guide.
VALVE SPRINGS
Free PRESSURE (LBS.)
Engine Length
9 Valve Closed Valve Open
2.25 liter
Inner 1.680" 17.701.462" | veus
Outer 1.822” [email protected]" | — А.........
ROCKER ARM ASSEMBLY OVERHAUL
Disassembly — 1) With rocker arm cover removed, loosen
tappet adjusting screws to remove load on rocker shaft.
2) Remove rocker shaft support bolts and lift off rocker arm
assembly.
3) Remove locating screw and washer from intermediate
rocker bracket. Withdraw all components from rocker shaft.
4) Inspect all components for wear. New bushings may be in-
stalled in rocker arms. Press out old bushing and press in new
bushings making sure oil holes are properly aligned. Ream
bushings to .530-.531”. Shaft-to-rocker arm clearance is
.0005-.0015".
Reassembly — 1) Install an intermediate rocker bracket with
locating screw through larger hole in shaft. Place remaining
components on shaft (see illustration).
2) Replace rocker arm assembly on cylinder head. Torque
bolts to specifications.
VALVE LIFTER SERVICE
Removal — 1) With cylinder head removed, remove tappet
guide locating bolts from right side of cylinder block.
CAUTION — Do not remove tappet guides before rollers are
withdrawn or rollers will fall into crankcase.
2) Using long nose pliers or wire, remove tappet slides. Keep
slides and all tappet parts in order for reassembly.
2EM5097 №
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Guide Locating Bolt
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TAPPET SLIDE REMOVAL
3) Remove rollers.
4) Withdraw tappet guides. If guides are difficult to remove
use Tool No. 530101 for removal.
ROCKER ARM ASSEMBLY
Copyright (c) 2003 Mitchell Repair Information Company
Rover Engines
5-393
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
Installation — 1) Fit tappet guides in block in proper
order, aligning locating holes. Screw in locating bolts enough
to hold guides in position.
2) Insert rollers with large chamfer facing forward.
3) Insert tappet slides with marking "FRONT" toward front of
engine.
4) Tighten tappet guide locating bolts and lockwire bolts in
pairs.
VALVE CLEARANCE ADJUSTMENT
Valve clearance is .010” intake and exhaust. To check
clearances, turn crankshaft until valves in first column are fully
open, then valves in second column may be checked and ad-
justed.
Valves Open Valves to Adjust
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Guide
Roller
2EM5099
ROLLER TAPPET ASSEMBLY
PISTONS, PINS, RINGS
PISTONS PINS RINGS
Engine Clearance Piston Fit Rod Fit Rings | End Gap | Side Clearance
2.25 Liter .0044-.0053" Push Fit By .0001-.0008" Comp. .010-.015" .0025-.0045"
Hand
Oil .015-.045" .0015-.0025"
OIL PAN REMOVAL
Drain oil, remove oil pan bolts and oil pan. Upon reinstallation
use new gasket, position oil pan and reinstall bolts.
PISTON & ROD INSTALLATION
Fit piston to connecting rod using new circlips. Fit rod to
crankshaft with rod number matching correct rod journal.
Torque rod caps to specifications and check end-play.
PISTON PIN REPLACEMENT
Remove piston circlips, push out piston pin. If rod small end
bushing is worn, replace. Press in new bushing and ream to
size, making sure oil holes are properly aligned. Pin must not
fall through piston, it is a push fit by hand. To check clearances
(see specifications).
FITTING PISTONS
Measure pistons at bottom of skirt at 90° to piston pin bore
approximately half way down. If a new standard size piston is
titted, make sure grade letters on block and piston are the
same. Grade letters are; "Z" is nominal to plus .0002", "A" is
plus .0002-.0004", "B" is plus .0004-.0006", "C" is plus .0006-
.0008” and “D” is plus .0008-.001”. If cylinder wear or taper
exceeds specifications, fit over size pistons. Oversize pistons
are not graded and come in .010", .020”,`.030” опа .040”
oversizes.
Place rings in cylinder bore and check end gaps. Fit the ex-
pander for the oil ring with ends over piston pin, with the side
rails one inch away. Fit compression rings in grooves with
markings “T" or TOP tacing upward.
Copyright (c) 2003 Mitchell Repair Information Company
5-394 Rover Engines
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
MAIN BEARINGS CONNECTING ROD BEARINGS
Thrust | Crankshaft
Engine Journal Diam. Clearance Bearing | Endplay | Journal Diam.| Clearance Sideplay
2.25 Liter 2.4995-2.500” .0008-.0022" Center .002-.006" } 2.312-2.31275"| .0007-.0025" .007-.012"
REPLACEMENT BEARINGS
Bearings for both crankshaft and connecting rods are
available in the following undersizes, .010”, .020”, .030” and
.040”.
CONNECTING RODS
1) Check connecting rod alignment. Assemble cap to rod
leaving out bearings halves. Torque rod nuts to 25 ft. lbs.
Loosen one nut and check joint to see that there is no clearance
between joint faces. If clearance exists, rod must be replaced.
2) Remove rod cap and place new bearings in rod. Fit cap
and torque rod nuts to 25 ft. lbs. Loosen one nut, using a .004-
.008” feeler gauge, insert between rod and cap. The bearing
crush may be adjusted by using slightly varying thickness of
bearing inserts to achieve proper gap.
3) Make a final check to prove bearing clearance, using a
.0025” shim paper. With shim paper inserted between rod half
and journal, rod should resist rotation and turn freely when
shim paper is removed.
4) Rods may also be checked using the Plastigage method to
determine clearance.
MAIN BEARINGS
1) Fit main bearing caps, less bearing halves. Torque bolts to
85 ft. Ibs. Loosen one bolt and check gap between cap and
block. If any gap is present cylinder block must be replaced.
2) Remove main bearing caps, place inserts in block and
caps. Torque cap bolts to 85 ft. Ibs. Loosen one bolt and check
gap between block and cap. It should be .004-.006". Gap may
be adjusted by using slightly varying thickness bearing inserts.
3) Make final check of main bearing clearance by inserting a
0025" shim paper between one half of bearing and
crankshaft. Torque cap bolts to specifications. Crankshaft
should resist rotation and with shim paper removed should be
free to turn. This procedure is done one bearing at a time.
4) Main bearings may also be checked using the Plastigage
method to determine clearance.
THRUST BEARING ALIGNMENT
1) Place crankshaft in position in crankcase. Mount a dial in-
dicator to read off end of crankshaft.
2) Check crankshaft end-play. If end-play is not to
specifications select thrust washers of proper thickness.
3) Place thrust washers with plated side toward crankshaft.
Right and left thrust washers must be within .003” of the same
thickness to maintain crankshaft centering in block. Thrust
washers are available in .0025", .005", .0075" and .010"
oversizes.
REAR MAIN BEARING OIL SEAL
Removal — 1) Remove hood, front floor seat base and
transmission. Place a block between flywheel housing and
chassis crossmember.
2) Remove starter, oil pan, clutch assembly and flywheel.
3) Attach a lifting sling to engine, apply sufficient tension to
support weight of engine.
4) Remove block placed between flywheel housing and
crossmember during transmission removal.
5) Remove flywheel housing and oil seal.
Oil Seal
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FLYWHEEL HOUSING SEAL
6) Remove rear main bearing cap, upper and lower oil seal
retainers and rear main bearing oil seal.
2EM5095
Installation — 1) Assemble seal retainer spring on
crankshaft by engaging hook and eye. CAUTION — Do not
stretch spring.
2) Apply silicone grease to oil seal journal and ends of oil
seal.
3) Open seal ends just enough to slide over crankshaft. Install
seal with spring groove towards flange (see illustration). Work
spring into groove with hook and eye at right angles to oil seal
ends.
Oil Seal
Seal Retainer Po 9
LA
2EM5096
REAR MAIN BEARING OIL SEAL
Copyright (c) 2003 Mitchell Repair Information Company
Rover Engines
5-395
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
4) Rotate seal until seal ends are facing toward cylinder
head.
5) Apply suitable sealer to seal retainer halves.
6) Attach vpper seal retainer half, leaving the two end bolts
finger tight.
7) Attach lower seal retainer half to main bearing cap in the
same manner as upper half.
8) Using silicone grease, fit "T” seals to main bearing cap.
Trim top edges of "T" seals to prevent them from fouling block
when being fitted.
9) Fit seal guides to crankcase. Install main bearing cap and
"T" seal to crankcase. Leaving .030" clearance between cap
and crankcase, check to see that all seals are properly
positioned.
10) Torque main bearing cap to 85 ft. Ibs. Fully tighten all
bolts of seal retainers. NOTE — Turn bolt heads so they will
clear flywheel housing seal.
11) Trim ends of "T" seals to leave .030" protruding from
bearing cap.
ENGINE FRONT COVER
Removal — 1) Remove hood, radiator, fan belt, starter
dog and crankshaft pulley.
2) Disconnect by-pass hose from thermostat housing.
3) Remove front cover nuts and bolts and remove cover.
4) Drive oil seal from front cover.
Installation — 1) Coat outside diameter of oil seal with
suitable sealing compound and press into front cover.
2) Smear grease on both sides of cover gasket and reinstall
front cover.
CAMSHAFT
Journal Diam.
Engine Clearance © | Lobe Lift
2.25 Liter
100000000000000000000088 | cocrornccrcerocrosAmes N eoorocuoroocoErteo:
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CAMSHAFT SPROCKET REPLACEMENT
1) With front cover removed, remove chain tensioner and tim-
ing chain.
2) Remove camshaft bolt, lock and washer.
3) To reinstall camshaft sprocket. See Valve Timing. After
sprocket is correctly on camshaft, replace washer, lock and
bolt.
CAMSHAFT & BEARING REPLACEMENT
Removal — 1) With camshaft sprocket removed, remove
thrust plate from camshaft. Extract camshaft using Tool No.
530101. NOTE — Before camshaft bearings may be removed,
engine must be removed and completely disassembled.
2) Drift out front and rear bearings and remove through side
cover openings.
3) Drift out two center bearings into distributor drive
chamber. Collapse bearings and remove from block, (see
illustration).
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CAMSHAFT BEARING REMOVAL
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2EM5200
Installation — 1) Position cylinder block vertical with rear
face down. Place one bearing, with single oil hole, over
number two bearing bore. Using suitable tools, press bearing
into block. Make sure oil holes are properly aligned.
2) Install front bearing, which has two oil holes. The small oil
hole aligns with vertical hole in block. Press bearing into block
until bearing is just below front face of cylinder block. NOTE
— Make sure bearing is pressed in far enough so that it will not
interfere with thrust plate.
3) Turn block over and install two rear bearings in the same
manner.
4) Place Guide Plug No. 274394 in front camshaft bearing.
Use two thrust plate retaining screws to secure plug.
5) Insert Reamer No. 274389 from rear of block into guide
plug in front bearing.
6) Locate guide collar, immediately in front of reamer cutter,
into rear most bearing, tighten screws retaining guide plug.
7) Ream two center and rear bearings. Remove guide plug
and ream front bearing. NOTE — No lubricant is used during
reaming, best results are achieved when bearings are cut dry.
Use compressed air to blow chips out of way while reaming.
8) Remove reamer handle and bolt. Remove reamer by tur-
ning in cutting direction.
9) Remove plugs from ends of oil gallery passages. Using
compressed air blow all chips out of oil passages and reinsert
plugs.
10) Screw plugs into rear of block, using new washers and
sealing compound.
11) Reinstall camshaft and thrust plate. Place camshaft
sprocket on shaft without using lock. Attach a dial indicator to
cylinder block so endplay of camshaft may be checked (see
specifications). If endplay is excessive replace thrust plate.
12) Reset valve timing and reassemble engine.
Copyright (c) 2003 Mitchell Repair Information Company
5-396 Rover Engines
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
VALVE TIMING
INTAKE EXHAUST
Open Close Open Close
Engine (BTDC) | (ABDC) | (BBDC) | (АТОС)
2.25 liter 6° 52° 34° 24° ©
\
TIMING CHAIN REPLACEMENT
Remove chain tensioner and lift off chain. Fit new chain and
see that there is no slack on drive side of chain, See Valve
Timing for adjustment procedure. Reinstall tensioner.
VALVE TIMING
1) Rotate crankshaft until timing mark in crankshaft pulley is
aligned with longest tongue on timing pointer (see
illustration). This is No. 1 piston at TDC.
2EM5208
Timing Pointer
TIMING MARKS
Front Cover
“ть.
2) Without moving crankshaft, remove pulley, timing pointer
and gear cover.
3) Fit camshaft sprocket, using keyway marked "P”. Rotate
camshaft until "P” mark is aligned with center of bolt hole (see
illustration).
O Oy 7. "pP"
2EM5209
VALVE TIMING MARK
4) Fit timing chain with no slack on drive side (see
illustration). If slack is present, slide camshaft sprocket off
camshaft, without moving shaft. Try alternate keyways until
one with no slack is found.
2EM5210
TIMING CHAIN POSITION
5) Install chain tensioner and tighten camshaft sprocket bolt
to specifications.
CAUTIÓN — When rotating crankshaft without timing chain
installed, camshaft may have to be rotated to prevent pistons
from interfering with valves.
ENGINE OILING
ENGINE OILING SYSTEM
Engine lubrication is by a gear type pump. Pump feeds oil to
an oil gallery from which oil feeds crankshaft main bearings.
Qil from main bearings goes through passages in crankshaft to
lubricate connecting rod journals. Oil passages from oil gallery
goes to rocker arm shaft, where rocker arms and valve stems
are oiled.
Crankcase Capacity — 7-4 gts. (with filter).
Oil Fitler Type & Replacement — Paper, Replace every 6,:
000 miles.
Normal Oil Pressure — 45-65 psi.
Pressure Regulator Valve — Non-adjustable.
Copyright (c) 2003 Mitchell Repair Information Company
Rover Engines
5-397
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
ENGINE OILING (Cont.)
OIL PUMP
Removal — 1) Remove oil pan and two bolts and tab
washers securing oil pump. Withdraw oil pump and oil pump
drive shaft.
2) Loosen oil screen lock-nut. Remove oil screen and sealing
ring.
| Pump Cover 2EM5204
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| | |
FD pl
Spring 79
Lock Nut
Plunger
Steel Ball
Oil Screen
| Tab Washer
Sealing Ring
OIL PUMP
3) Remove oil pump cover and pump gears.
4) Remove plug for oil pressure relief valve. Remove spring,
plunger and ball.
5) Replace idler gear bushing if worn. Press in new bushing
and drill .125” diameter lubrication hole. Ream bushing to
.500”.
Drill Chuck —
2EM5205
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PRESSURE RELIEF VALVE LAPPING
6) Inspect pressure relief valve seat. If necessary, lap seat with
a steel ball (Rover Part No. 3748) soldered to a piece of tub-
ing. Chuck tool in drill press and lap with a coarse compound.
Finish by hand lapping with a fine compound. Thoroughly
clean after lapping.
7) Check end-play of oil pump gears (see specifications).
Install drive gear with plain side of gear bore facing up (see
illustration).
Plain Side
Idler Gear
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OIL PUMP GEARS
8) Coat faces of pump body and cover with sealing com-
pound. Replace cover and screws.
9) Install pressure relief valve assembly. Concave end of
plunger must face toward steel ball.
10) Replace oil screen. Position oil screen so it will be square
with pan baffle plate.
11) Insert longer splined end of pump drive shaft into pump.
12) Insert pump and drive shaft into engine block, engaging
drive shaft splines.
13) Reinstall two pump bolts and tab washers. Refit oil pan.
Oil Pump Specifications
Pump Gear Endplay
Steel Gear era .002-.005”
Aluminium Gear... .003-.006"
Radical Clearance of Gears... .001-.004"
Backlash of Gears... nn. .006-.012"
Reliet Valve Spring
Free Length...........................eiic erre e eee 2.670"
Compressed Length.......................... e... 2.450"
Copyright (c) 2003 Mitchell Repair Information Company
5-398
Rover Engines
1971-72 LAND ROVER 2.25 LITER 4 CYLINDER (Cont.)
ENGINE-COOLING
Cooling System Specifications
Radiator Capacity — 8.5 gts.
Radiator Cap — 9 psi.
TIGHTENING SPECIFICATIONS
Application Torque (Ft. Lbs.)
Rod O7] ee ee. 25
Main Bearing Cap............…..…...……rrscerercccssssnsarercsssren sens 85
Cylinder Head (5/16")...........…….….rrersssseressansensessensans 18
(1/2) eee, 65
Rocker Shaft (5/16") eee, 18
(1/2) ee sree 65
Starter Dog.....................eeerreccecere ree DA 150
Flywheel .........................000rmmmrcencecceee o are ee e 60-65
Clutch Cover...................e....0000eceeee eee 22-25
Copyright (c) 2003 Mitchell Repair Information Company
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