Rover 214 & 414 Service and Repair Manual - Rover club

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Chapter 9 Braking system Contents Anti-lock Braking System (ABS) - component removal and refitting . . 26 Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . 12 Front brake disc - inspection, removal and refitting . . . . . . . . . . . . . 13 Front brake pads - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1 Handbrake cables - removal and refitting . . . . . . . . . . . . . . . . . . . . . 24 Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic fluid - level check and renewal . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic pipes and hoses - inspection . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic pipes and hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Degrees of difficulty Easy, suitable for novice with little experience 1 Specifications Fairly easy, suitable for beginner with some experience 2 Fairly difficult, suitable for competent DIY mechanic 1689 Rover 214 & 414 Updated Version 09/97 9•1 Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 9 Pressure regulating valve - testing, removal and refitting . . . . . . . . . 14 Rear brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 21 Rear brake disc - inspection, removal and refitting . . . . . . . . . . . . . 22 Rear brake drum - removal, inspection and refitting . . . . . . . . . . . . . 17 Rear brake pads - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rear brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rear brake shoes - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 18 Stop lamp switch - removal, refitting and adjustment . . . . . . . . . . . 25 Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . 3 Vacuum servo unit check valve - removal, testing and refitting . . . . 4 Difficult, suitable for experienced DIY mechanic Very difficult, suitable for expert DIY or professional Brake system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual hydraulic circuit, split diagonally on models without ABS and front to rear on models with ABS. Disc front brakes. Drum rear brakes except on models with ABS which have rear disc brakes. Vacuum servo-assistance on all models. Cable-operated handbrake on rear brakes Front brakes Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc, with single piston sliding caliper Disc diameter: Non-ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 mm ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 mm Disc thickness: New: Non-ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80 mm ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.60 mm Minimum thickness after machining: Non-ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.70 mm ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm Maximum disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm Brake pad friction material minimum thickness . . . . . . . . . . . . . . . . . . . 3.0 mm 3 4 5 9
9•2 Braking system Rear brakes Non-ABS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum diameter: Single leading shoe drum New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm Maximum diameter after machining . . . . . . . . . . . . . . . . . . . . . . . . . . 204 mm Maximum drum ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 mm Brake shoe friction material minimum thickness . . . . . . . . . . . . . . . . . . ABS 2.0 mm Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc, with single piston sliding caliper Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc thickness: 239 mm New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm Minimum thickness after machining . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm Maximum disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm Brake pad friction material minimum thickness . . . . . . . . . . . . . . . . . . . 3.0 mm Torque wrench settings Nm lbf ft Servo vacuum hose-to-inlet manifold union bolt . . . . . . . . . . . . . . . . . . 50 37 Brake hose union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28 Master cylinder-to-servo unit nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 13 Master cylinder brake pipe union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18 Brake caliper guide pin bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 24 Brake disc retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9 Front brake caliper bracket-to-hub bolts . . . . . . . . . . . . . . . . . . . . . . . . 81 60 Pressure regulating valve union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 10 Rear brake drum retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Rear wheel cylinder-to-backplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Rear brake caliper bracket-to-trailing arm bolts . . . . . . . . . . . . . . . . . . . 40 30 Handbrake cable-to-underbody retaining bolts . . . . . . . . . . . . . . . . . . . 22 16 ABS modulator mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS modulator brake pipe union nuts: 7 5 Upper union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Lower union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18 ABS front wheel sensor retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 ABS rear wheel sensor retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 ABS wheel sensor wiring bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 ABS rear wheel sensor cover and cover strap bolts . . . . . . . . . . . . . . . 10 7 Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 74 1 Primary hydraulic circuit 2 Secondary hydraulic circuit 3 Brake pipe - pressure regulating valve to right-hand front hose 4 Brake pipe - pressure regulating valve to left-hand front hose 5 Brake pipe - pressure regulating valve to right-hand rear hose 6 Brake pipe - pressure regulating valve to left-hand rear hose 7 Brake pipe - hose to rear wheel cylinder 8 Brake flexible hose - brake pipe to front brake caliper 9 Brake flexible hose - rear wheel 10 Handbrake cable 11 Pressure regulating valve 1.0a Non-ABS braking system component layout 1689 Rover 214 & 414 Updated Version 09/97
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Rover 214 & 414 Service and Repair
Page 3 and 4:
REPAIRS AND OVERHAUL Engine and Ass
Page 5 and 6:
Working on your car can be dangerou
Page 7 and 8:
Jump starting will get you out of t
Page 9 and 10:
Puddles on the garage floor or driv
Page 11 and 12:
Engine oil level Before you start 4
Page 13 and 14:
Power steering fluid level Before y
Page 15 and 16:
Electrical system 4 Check all exter
Page 17 and 18:
Chapter 2 Part A Engine in-car repa
Page 19 and 20:
Valves Seat angle: Inlet . . . . .
Page 21 and 22:
The crankshaft runs in five main be
Page 23 and 24:
5.14 Cylinder head cover bolt tight
Page 25 and 26:
8.6 Crankshaft pulley mark aligned
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1 Timing belt upper righthand (oute
Page 29 and 30:
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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port with a wad of clean cloth to p
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15.9 Inlet manifold pre-heater temp
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18.1b Exhaust system components - w
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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 and 140: 5B•2 Ignition system - fuel injec
Page 141 and 142: Chapter 5 Part C Starting and charg
Page 143 and 144: 4.4 Battery clamp bolt 4 Battery -
Page 145 and 146: 9 Starting system - testing 2 1 If
Page 147: 11.14 Unscrew nut and disconnect st
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
Page 191 and 192: 3.10a Unclip plastic cover . . . Un
Page 193 and 194: 4.22 Driver’s side window switch
Page 195 and 196: 5.20b Rear cluster tail lamp bulb i
Page 197 and 198: 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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