Rover 214 & 414 Service and Repair Manual - Rover club

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2A•2 Engine in-car repair procedures Crankshaft Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing journal size grades: 47.979 to 48.000 mm Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.993 to 48.000 mm Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.986 to 47.993 mm Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.979 to 47.986 mm Crankpin journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankpin journal size grades: 42.986 to 43.007 mm Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.000 to 43.007 mm Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.993 to 43.000 mm Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.986 to 42.993 mm Main bearing and crankpin journal maximum ovality . . . . . . . . . . . . . . . 0.010 mm Main bearing and big-end bearing running clearance . . . . . . . . . . . . . . Crankshaft endfloat: 0.021 to 0.049 mm Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 to 0.30 mm Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm Thrustwasher thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gudgeon pins 2.61 to 2.65 mm Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.0 mm Fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and piston rings Note: Service pistons are Grade B Interference Piston diameter: Grade A Grade B K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.940 to 74.955 mm 74.956 to 74.970 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston-to-bore clearance: 74.945 to 74.960 mm 74.960 to 74.975 mm K8 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 to 0.045 mm K16 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.040 mm Service limit - all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring end gaps (fitted 20 mm from top of bore): Top compression ring: 0.080 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.45 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.50 mm Second compression ring - all models . . . . . . . . . . . . . . . . . . . . . . . . Oil control ring: 0.30 to 0.50 mm K8 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16: 0.25 to 1.00 mm standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.50 mm service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring-to-groove clearance: Top compression ring: 0.60 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 to 0.09 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second compression ring: 0.04 to 0.07 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 to 0.08 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 to 0.07 mm Oil control ring - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head 0.02 to 0.06 mm Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium alloy Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.95 to 119.05 mm Reface limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm Maximum acceptable gasket face distortion . . . . . . . . . . . . . . . . . . . . . 0.05 mm Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat cutter correction angle: 1.5 mm Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve stem installed height: K8: 60° new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.95 to 40.81 mm service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16: 41.06 mm new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.93 to 39.84 mm service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm 1689 Rover 214 & 414 Updated Version 09/97
Valves Seat angle: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head diameter: Inlet: 44° 30’ K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.0 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust: 28.0 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem outside diameter: Inlet: 24.0 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.967 to 6.975 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust: 5.952 to 5.967 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.952 to 6.967 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guide inside diameter: 5.947 to 5.962 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.000 to 7.025 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem-to-guide clearance: Inlet: 6.000 to 6.025 mm standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 to 0.04 mm service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust: 0.07 mm standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 to 0.08 mm service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing: K8: 0.11 mm Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16: 7° ATDC Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve spring free length: 5° ATDC K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.2 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.0 mm Valve guide fitted height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 6.0 mm Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toothed belt Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing journal running clearance: 6 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 to 0.094 mm Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft endfloat: 0.150 mm Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 to 0.190 mm Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve lift: 0.500 mm K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 mm K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 mm Hydraulic tappet outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication system 32.959 to 32.975 mm System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 bar @ idle speed Oil pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump clearances: Trochoidal, eccentric-rotor Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 to 0.06 mm Outer rotor-to-body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.28 to 0.36 mm Rotor lobe clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.13 mm Pressure relief valve operating pressure . . . . . . . . . . . . . . . . . . . . . . . . 4.1 bar Oil pressure warning lamp lights at . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below 0.3 to 0.5 bar 1689 Rover 214 & 414 Updated Version 09/97 Engine in-car repair procedures 2A•3 2A
Page 1 and 2: 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: Chapter 2 Part A Engine in-car repa
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
Page 27 and 28: 1 Timing belt upper righthand (oute
Page 29 and 30: 9.39 Ensure timing belt tensioner s
Page 31 and 32: 11.9 Secure partly-removed timing b
Page 33 and 34: 12 Valve clearances - general infor
Page 35 and 36: tightens each bolt through half a t
Page 37 and 38: 16.12 Oil pump outer rotor outside
Page 39 and 40: front of the vehicle and support it
Page 41 and 42: 2B•2 Engine removal and general o
Page 49 and 50: 2B•10 Engine removal and general
Page 57 and 58: Chapter 3 Cooling, heating and vent
Page 59 and 60: 4 Cooling system hoses - renewal 2
Page 61 and 62: 6.7 Testing the thermostat Ensure t
Page 63 and 64: 9.10 Inlet manifold pre-heater temp
Page 65 and 66: 10.5b . . . and disengage duct from
Page 67 and 68: 10.20d Remove fan retaining nut . .
Page 69 and 70:
17 Working from inside the vehicle,
Page 71 and 72:
3•2 Cooling, heating and ventilat
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
Page 79 and 80:
3•10 Cooling, heating and ventila
Page 81 and 82:
3•12 Cooling, heating and ventila
Page 83 and 84:
Chapter 4 Part A Fuel and exhaust s
Page 85 and 86:
3.4 Slacken clamp to disconnect int
Page 87 and 88:
8.3 Removing cover retaining bolt (
Page 89 and 90:
port with a wad of clean cloth to p
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 109 and 110:
Page 111 and 112:
Page 113 and 114:
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 135 and 136:
Page 137 and 138:
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 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 179 and 180:
Page 181 and 182:
10•16 Suspension and steering 1 H
Page 183 and 184:
Page 185 and 186:
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
Page 199 and 200:
13.2a Carefully prise out clock mou
Page 201 and 202:
16.7 Disconnect Lucar connection an
Page 203 and 204:
21.5 Removing tailgate washer jet -
Page 205 and 206:
24.3a Use DIN tools to release reta
Page 207 and 208:
Key to wiring diagrams (continued)
Page 209 and 210:
1689 Rover 214 & 414 Updated Versio
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
Page 217:
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Rover 214 & 414 Service and Repair Manual - Rover club

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