Rover 214 & 414 Service and Repair Manual Mark Coombs and Christopher Rogers Models covered Rover 214 and 414 models fitted with eight or sixteen-valve 1397 cc `K-series' engine Covers major mechanical features of Cabriolet Does not cover Diesel engine models (1689-288-9AA3) © Haynes Publishing 1997 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. ISBN 1 85960 458 7 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 PARIS, France Haynes Publishing Nordiska AB Fyrisborgsgatan 5, 754 50 Uppsala, Sverige 1689 Rover 214 & 414 Updated Version 09/97 Contents REPAIRS AND OVERHAUL Engine and Associated Systems Engine in-car repair procedures Engine removal and general overhaul procedures Cooling, heating and ventilation systems Fuel and exhaust systems - carburettor engines Fuel and exhaust systems - single-point fuel injected engines Fuel and exhaust systems - multi-point fuel injected engines Emission control systems Ignition system - carburettor engines Ignition system - fuel injected engines Starting and charging systems Page 2A·1 Page 2B·1 Page 3·1 Page 4A·1 Page 4B·1 Page 4C·1 Page 4D·1 Page 5A·1 Page 5B·1 Page 5C·1 Transmission Clutch Gearbox Driveshafts Page Page Page 6·1 7·1 8·1 Brakes and Suspension Braking system Suspension and steering Page 9·1 Page 10·1 Body Equipment Bodywork and fittings Body electrical systems Page 11·1 Page 12·1 Wiring Diagrams Page 12·20 REFERENCE Dimensions and Weights Conversion Factors Buying Spare Parts and Vehicle Identification General Repair Procedures Jacking and Vehicle Support Radio/cassette Anti-theft System - precaution Tools and Working Facilities MOT Test Checks Fault Finding Glossary of Technical Terms Page REF·1 Page REF·2 Page REF·3 Page REF·4 Page REF·5 Page REF·5 Page REF·6 Page REF·8 Page REF·12 Page REF·19 Index Page REF·24 1689 Rover 214 & 414 Updated Version 09/97 2A·1 Chapter 2 Part A Engine in-car repair procedures Contents Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshafts and hydraulic tappets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression test - description and interpretation . . . . . . . . . . . . . . Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head cover - removal and refitting . . . . . . . . . . . . . . . . . . . Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine/gearbox mountings - inspection and renewal . . . . . . . . . . . . Flywheel - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 10 11 3 17 6 13 5 2 19 18 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing belt - removal, inspection, refitting and adjustment . . . . . . . Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . Timing belt tensioner and sprockets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top Dead Centre (TDC) for number one piston - locating . . . . . . . . Valve clearances - general information . . . . . . . . . . . . . . . . . . . . . . . 1 16 15 14 8 7 9 4 12 Degrees of difficulty Easy, suitable for novice with little experience 1 Fairly easy, suitable for beginner with some experience 2 Fairly difficult, suitable for competent DIY mechanic 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 2A Specifications General Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Designation: 1.4 8-valve sohc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 16-valve dohc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum compression pressure difference between cylinders . . . . . . Maximum power (EEC): K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K8 (with catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 (with catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum torque (EEC): K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 (with catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder in-line, four-stroke, liquid-cooled K8 K16 75.00 mm 79.00 mm 1396 cc 1-3-4-2 (No 1 cylinder at timing belt end) Clockwise (seen from right-hand side of vehicle) 9.75 : 1 9.50 : 1 10.3 bar 1.4 bar 76 ps (56 kW) @ 5700 rpm 75 ps (55 kW) @ 5500 rpm 95 ps (70 kW) @ 6250 rpm 90 ps (66 kW) @ 6250 rpm 117 Nm (86 lbf ft) @ 3500 rpm 124 Nm (91 lbf ft) @ 4000 rpm 120 Nm (89 lbf ft) @ 4000 rpm Cylinder block/crankcase Note: Service liners are Grade B Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner bore diameter - 60 mm from top of bore: Standard - grade A (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard - grade B (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium alloy 74.975 to 74.985 mm 74.986 to 74.995 mm 75.045 mm 1689 Rover 214 & 414 Updated Version 09/97 2A·2 Engine in-car repair procedures Crankshaft Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing journal size grades: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankpin journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankpin journal size grades: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing and crankpin journal maximum ovality . . . . . . . . . . . . . . . Main bearing and big-end bearing running clearance . . . . . . . . . . . . . . Crankshaft endfloat: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thrustwasher thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 47.979 to 48.000 mm 47.993 to 48.000 mm 47.986 to 47.993 mm 47.979 to 47.986 mm 42.986 to 43.007 mm 43.000 to 43.007 mm 42.993 to 43.000 mm 42.986 to 42.993 mm 0.010 mm 0.021 to 0.049 mm 0.10 to 0.30 mm 0.50 mm 2.61 to 2.65 mm Gudgeon pins Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fit in connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.0 mm Interference Pistons and piston rings Note: Service pistons are Grade B Piston diameter: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston-to-bore clearance: K8 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service limit - all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring end gaps (fitted 20 mm from top of bore): Top compression ring: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second compression ring - all models . . . . . . . . . . . . . . . . . . . . . . . . Oil control ring: K8 - standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16: standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring-to-groove clearance: Top compression ring: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second compression ring: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil control ring - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grade A 74.940 to 74.955 mm 74.945 to 74.960 mm 0.015 to 0.045 mm 0.010 to 0.040 mm 0.080 mm Grade B 74.956 to 74.970 mm 74.960 to 74.975 mm 0.25 to 0.45 mm 0.30 to 0.50 mm 0.30 to 0.50 mm 0.25 to 1.00 mm 0.25 to 0.50 mm 0.60 mm 0.04 to 0.09 mm 0.04 to 0.07 mm 0.04 to 0.08 mm 0.04 to 0.07 mm 0.02 to 0.06 mm Aluminium alloy 118.95 to 119.05 mm 0.20 mm 0.05 mm 45° 1.5 mm 30° 60° Cylinder head Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reface limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum acceptable gasket face distortion . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat cutter correction angle: Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve stem installed height: K8: new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . service limit . . . . . . . . . . . . . . . . ...