Rover 214 & 414 Service and Repair Manual - Rover club

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6.3 Removing crankshaft sensor (wiring lead screw arrowed) 6 Crankshaft sensor and reluctor ring - removal and refitting 3 Removal Crankshaft sensor 1 Disconnect the battery negative terminal. 2 Disconnect the sensor wiring at its connector plug on the flywheel rear cover plate, then undo the retaining screw to release the wiring lead. 3 Remove the two retaining screws and withdraw the sensor from the cylinder block/crankcase (see illustration). 4 Inspect the sensor for obvious signs of wear or damage and renew it if necessary. No data is available to enable the sensor to be tested. If thought to be faulty, it can be checked only by substitution with a new component. Reluctor ring 5 Remove the flywheel. 6 Undo the two screws securing the reluctor ring to the rear of the flywheel and withdraw it (see illustration). 6.6 Reluctor ring-to-flywheel screws (arrowed) 7 Check the ring for obvious signs of wear or damage and renew it if necessary. Refitting Crankshaft sensor 8 Ensure that the sensor and cylinder block/crankcase mating surfaces are clean then refit the sensor and tighten its retaining screws to the specified torque. 9 Connect the sensor wiring connector and tighten the connector mounting screw to the specified torque. 10 Reconnect the battery negative terminal. Reluctor ring 11 Refitting is a reversal of the removal procedure. Tighten the reluctor retaining screws to the specified torque. 7 Engine management electronic control unit (ECU) - removal and refitting Refer to Chapter 4. 1689 Rover 214 & 414 Updated Version 09/97 Ignition system – fuel injection engines 5B•3 8 Ignition timing - checking and adjustment Refer to Chapter 1. 9 Ignition system - testing 5 1 If a fault appears in the engine management (ignition/fuel) system, first ensure that the fault is not due to poor maintenance. Check that the air cleaner filter element is clean, the spark plugs are in good condition and correctly gapped, and that the engine breather hoses are clear and undamaged. Also check that the accelerator cable is correctly adjusted. If the engine is running very roughly, check the compression pressures, bearing in mind that possibly one of the hydraulic tappets might be faulty, producing an incorrect valve clearance. 2 If these checks fail to reveal the cause of the problem, the vehicle should be taken to a suitably-equipped Rover dealer for testing. A wiring block connector is incorporated in the engine management circuit into which a special electronic diagnostic tester can be plugged. The tester will locate the fault quickly and simply, alleviating the need to test all the system components individually, which is a time-consuming operation that carries a high risk of damaging the ECU. 3 The only ignition system checks which can be carried out by the home mechanic are those described for the spark plugs, HT leads, rotor arm and distributor cap (Chapter 1), and the ignition HT coil (this Chapter). If necessary, the system wiring and wiring connectors can be checked as described in Chapter 12, ensuring that the ECU wiring connectors have first been disconnected. 5B
Chapter 5 Part C Starting and charging systems Contents Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator brush holder and voltage regulator - renewal . . . . . . . . . 7 Alternator drivebelt - inspection, adjustment and renewal . . . . . . . . 6 Battery - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery - testing and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Degrees of difficulty Easy, suitable for novice with little experience 1 Specifications Fairly easy, suitable for beginner with some experience System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, negative earth 2 Fairly difficult, suitable for competent DIY mechanic 1689 Rover 214 & 414 Updated Version 09/97 5C•1 Charging system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1 Starter motor - brush and solenoid renewal . . . . . . . . . . . . . . . . . . . 11 Starter motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 10 Starting system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Difficult, suitable for experienced DIY mechanic Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas code: Maintenance-free (sealed for life) lead-acid Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 063 Cold climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 063S Performance: Cold cranking Reserve capacity 063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 amps 60 amps 063S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 405 amps 70 amps Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas/Magneti Marelli A127-65 Output - @ 14 volts and 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 amps Regulated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 volts maximum Brush minimum protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm approx. Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter motor Lucas 21TR Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas M79 Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 kW Brush minimum length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 mm approx. Torque wrench settings Alternator Nm lbf ft Pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Mounting/pivot/adjusting arm bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter motor 25 18 Motor-to-gearbox bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor support bracket fasteners: 45 33 Bracket front half-to-motor nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Bracket front half-to-rear half bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33 Bracket rear half-to-gearbox bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 3 4 Very difficult, suitable for expert DIY or professional 5 5C
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Rover 214 & 414 Service and Repair
Page 3 and 4:
REPAIRS AND OVERHAUL Engine and Ass
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Working on your car can be dangerou
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Jump starting will get you out of t
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Puddles on the garage floor or driv
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Engine oil level Before you start 4
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Power steering fluid level Before y
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Electrical system 4 Check all exter
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Chapter 2 Part A Engine in-car repa
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Valves Seat angle: Inlet . . . . .
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The crankshaft runs in five main be
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5.14 Cylinder head cover bolt tight
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8.6 Crankshaft pulley mark aligned
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1 Timing belt upper righthand (oute
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9.39 Ensure timing belt tensioner s
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11.9 Secure partly-removed timing b
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12 Valve clearances - general infor
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tightens each bolt through half a t
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16.12 Oil pump outer rotor outside
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front of the vehicle and support it
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2B•2 Engine removal and general o
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2B•10 Engine removal and general
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Chapter 3 Cooling, heating and vent
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4 Cooling system hoses - renewal 2
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6.7 Testing the thermostat Ensure t
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9.10 Inlet manifold pre-heater temp
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10.5b . . . and disengage duct from
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10.20d Remove fan retaining nut . .
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17 Working from inside the vehicle,
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3•2 Cooling, heating and ventilat
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3•10 Cooling, heating and ventila
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3•12 Cooling, heating and ventila
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Chapter 4 Part A Fuel and exhaust s
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3.4 Slacken clamp to disconnect int
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8.3 Removing cover retaining bolt (
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Page 91 and 92: 15.9 Inlet manifold pre-heater temp
Page 93 and 94: 18.1b Exhaust system components - w
Page 95 and 96: Chapter 4 Part B Fuel and exhaust s
Page 97 and 98: eturn to the tank swirl pot, where
Page 99 and 100: 6.7 Slackening pressure release bol
Page 101 and 102: 15.1 Disconnecting fuel feed and re
Page 103 and 104: 15.26 Absolute pressure sensor fuel
Page 105 and 106: 18 Exhaust manifold - removal and r
Page 107 and 108: 4C•2 Fuel and exhaust systems - m
Page 115 and 116: Chapter 4 Part D Emission control s
Page 117 and 118: 3.8 Disconnecting multiplug from pu
Page 119 and 120: Chapter 3 Cooling, heating and vent
Page 121 and 122: 4 Cooling system hoses - renewal 2
Page 123 and 124: 6.7 Testing the thermostat Ensure t
Page 125 and 126: 9.10 Inlet manifold pre-heater temp
Page 127 and 128: 10.5b . . . and disengage duct from
Page 129 and 130: 10.20d Remove fan retaining nut . .
Page 131 and 132: 17 Working from inside the vehicle,
Page 133 and 134: 5A•2 Ignition system - carburetto
Page 139: 5B•2 Ignition system - fuel injec
Page 143 and 144: 4.4 Battery clamp bolt 4 Battery -
Page 145 and 146: 9 Starting system - testing 2 1 If
Page 147 and 148: 11.14 Unscrew nut and disconnect st
Page 149 and 150: 9•2 Braking system Rear brakes No
Page 151 and 152: 9•4 Braking system shut down and
Page 153 and 154: 9•6 Braking system 6.21 Using a o
Page 155 and 156: 9•8 Braking system piston in as f
Page 157 and 158: 9•10 Braking system the caliper p
Page 159 and 160: 9•12 Braking system 1 Brake drum
Page 161 and 162: 9•14 Braking system 18.3 Wheel cy
Page 163 and 164: 9•16 Braking system 15 Inspect al
Page 165 and 166: 9•18 Braking system 1 Servo unit
Page 167 and 168: 10•2 Suspension and steering Whee
Page 169 and 170: 10•4 Suspension and steering opti
Page 171 and 172: 10•6 Suspension and steering 5.4
Page 173 and 174: 10•8 Suspension and steering 9.4
Page 175 and 176: 10•10 Suspension and steering 11.
Page 177 and 178: 10•12 Suspension and steering 8 R
Page 181 and 182: 10•16 Suspension and steering 1 H
Page 187 and 188: Chapter 12 Body electrical systems
Page 189 and 190: 1 General information and precautio
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3.10a Unclip plastic cover . . . Un
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4.22 Driver’s side window switch
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5.20b Rear cluster tail lamp bulb i
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16 Refitting is a reversal of the r
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13.2a Carefully prise out clock mou
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16.7 Disconnect Lucar connection an
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21.5 Removing tailgate washer jet -
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24.3a Use DIN tools to release reta
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Key to wiring diagrams (continued)
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1689 Rover 214 & 414 Updated Versio
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Rover 214 & 414 Service and Repair Manual - Rover club

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