Rover 414 (1997) manual

1689 Rover 214 & 414 Updated Version 09/97 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 Publishin[...]

1689 Rover 214 & 414 Updated Version 09/97 REP AIRS AND OVERHAUL Engine and Associated Systems Engine in-car repair procedures Page 2A•1 Engine removal and general overhaul procedures Page 2B•1 Cooling, heating and ventilation systems Page 3•1 Fuel and exhaust systems - carburettor engines Page 4A•1 Fuel and exhaust systems - single-poi[...]

2A 1689 Rover 214 & 414 Updated Version 09/97 Chapter 2 Part A Engine in-car r epair pr ocedur es Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Camshafts and hydraulic tappets - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Crankshaft Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.979 to 48.000 mm Main bearing journal size grades: Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Valves Seat angle: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° 30’ Head diameter: Inlet: K8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Torque wrench settings Nm lbf ft Spark plug (HT) lead clip screws - K8 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7 Air intake duct support bracket-to-cylinder head screws . . . . . . . . . . . 4 3 Spark plug cover screws - K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.5 Cylinder head cover bolts . . . . . . . . .[...]

The crankshaft runs in five main bearings. Thrustwashers are fitted to the centre main bearing (upper half) to control crankshaft endfloat. The connecting rods rotate on horizontally- split bearing shells at their big-ends. The pistons are attached to the connecting rods by gudgeon pins which are an interference fit in the connecting rod small-end [...]

4 Top Dead Centre (TDC) for number one piston - locating 2 General 1 The crankshaft pulley, crankshaft and camshaft sprockets are provided by the factory with clear marks which align only at 90° BTDC. This positions the pistons half-way up the bores so that there is no risk of damage as the engine is reassembled. These marks do not indicate TDC. U[...]

13 Refit the cover to the cylinder head, ensuring that the seal remains seated in its groove. Fit all bolts, finger-tight. 14 Tighten the cylinder head cover bolts in the sequence shown to the specified torque wrench setting (see illustration) . 15 Refit the timing belt upper right- hand/outer cover to the cylinder head cover and tighten all the di[...]

2 Unscrew the remaining cover retaining bolts and withdraw the cover, noting the rubber seal fitted to the mounting bracket edge. Note that if the cover is not slotted at the bottom corner screw’s location, the screw will have to be removed fully. If this is the case, the cover can be slotted to ease future removal and refitting (see illustration[...]

clear of the timing belt covers. Take great care not to place any undue strain on hoses and mop up any spilt fluid immediately. 3 Remove the timing belt upper right-hand (outer) cover. 4 Firmly apply the handbrake then jack up the front of the vehicle and support it on axle stands. Remove the right-hand roadwheel 5 From underneath the front of the [...]

c) Crankshaft sprocket - The two dots must be positioned on each side of the raised rib on the oil pump body (see illustration) . 16 If a used belt is being refitted, ensure that the arrow mark made on removal points in the normal direction of rotation. Fit the timing belt over the crankshaft and camshaft sprockets, ensuring that the belt front run[...]

component needs to be removed at the same time, start by removing the timing belt, then remove each component as described below whilst ignoring the preliminary dismantling steps. Removal 1 Disconnect the battery negative lead. 2 To improve access to the timing belt components (see illustrations) , remove the expansion tank mounting bolts then free[...]

loose fit in the camshaft end, remove it and store it with the sprocket for safe-keeping. Crankshaft sprocket 13 On K16 engines, use the tool described in paragraph 11 to lock together the camshaft sprockets so that they cannot move under valve spring pressure when the timing belt is removed. 14 Remove the crankshaft pulley and timing belt lower co[...]

Tensioner pulley 39 Refit the tensioner pulley assembly and tighten the pulley Allen screw and the backplate clamp bolt lightly. Hook the tensioner spring over the pillar bolt and check that the tensioner is free to move under spring tension and that the pulley bears correctly against the timing belt (see illustration) . 40 On K16 engines, remove t[...]

2A•14 Engine in-car r epair procedur es 1689 Rover 214 & 414 Updated Version 09/97 11.0a Top end components - K8 engine 11.0b Top end components - K16 engine 1 Cylinder head cover 2 Seal 3 Engine oil filler cap 4 Seal 5 Bolt 6 HT lead retaining clip bracket 7 Screw 8 HT lead retaining clip 9 HT lead retaining clip 10 HT lead retaining clip br[...]

time to refill with oil on restarting the engine, resulting in incorrect valve clearances. K16 engines 9 Remove both camshaft sprockets, then unscrew the inner cover’s upper retaining bolts so that the cover can be pulled away from the cylinder head just far enough for adequate working clearance. Take care not to distort or damage the cover or th[...]

29 Working in the sequence shown (see illustration) , progressively tighten the camshaft bearing cap bolts by one turn at a time until the caps touch the cylinder head evenly. Now go round again, working in the same sequence, and tighten all the bolts to the specified torque setting. Work only as described to impose the pressure of the valve spring[...]

12 Valve clearances - general information 1 It is necessary for a clearance to exist between the tip of each valve stem and the valve operating mechanism. This allows for expansion of the various engine components as the engine reaches normal operating temperature. 2 On most older engine designs, this meant that the valve clearances (also known as [...]

the cylinder block/crankcase as it is located by dowels as well as by the tops of the liners. 17 With the joint broken, lift the cylinder head away, using assistance if possible as it is a heavy assembly, especially if complete with the manifolds. Remove the gasket, noting the two locating dowels, and discard it. 18 Further to the warnings given in[...]

tightens each bolt through half a turn so that the marks face away from each other and the third stage tightens them through another half-turn so that all the bolt-head marks will then align again with their cylinder head counterparts. If any bolt is overtightened past its mark, slacken it through 90°, then re- tighten until the marks align (see i[...]

area so that it cannot be contaminated with oil. 2 Drain the engine oil, then clean and refit the engine oil drain plug, tightening it to the specified torque wrench setting. If the engine is nearing its service interval when the oil and filter are due for renewal, it is recommended that the filter is also removed and a new one fitted. After reasse[...]

ensuring that the outer rotor’s identification mark faces outwards (see illustration) . 13 Fit a new sealing ring to the pump body and refit the cover plate. Apply thread-locking compound to the threads of the cover plate Torx screws and tighten them securely. 14 Check that the pump rotates freely, then prime it by injecting oil into its passages[...]

reservoir out of its retaining clip and position it clear of the timing belt covers. Take great care not to place any undue strain on hoses and mop up any spilt fluid immediately. 7 Support the weight of the engine/gearbox unit by using a trolley jack, with a wooden spacer to prevent damage to the sump. Unscrew the mounting through-bolt and nut and[...]

front of the vehicle and support it securely on axle stands. 26 Support the weight of the engine/gearbox unit by using a trolley jack, with a wooden spacer to prevent damage to the transmission casing. Unbolt the mounting bracket from the gearbox and the connecting link from the underbody bracket, then remove the mounting (see illustrations) . 27 U[...]

2B 1689 Rover 214 & 414 Updated Version 09/97 Chapter 2 Part B Engine r emoval and general overhaul pr ocedur es Crankshaft - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Crankshaft - refitting and main bearing running clearance check . . 18 Crankshaft - removal . . . . . . . . . . . . . . . . . . . . . . [...]

Loss of power, rough running, knocking or metallic engine noises, excessive valve gear noise and high fuel consumption may also point to the need for an overhaul, especially if they are all present at the same time. An engine overhaul involves restoring all internal parts to the specification of a new engine. During an overhaul, the cylinder liners[...]

12 Trace the clutch cable back from the clutch release lever to the bulkhead and remove the C-clip which retains the outer cable spring in position. Unhook the inner cable from the release lever and free the outer cable from its mounting bracket and position it clear of the gearbox. 13 From underneath the vehicle, pull out the rubber retaining pin [...]

out over the front of the body and lower the unit to the ground (see illustration) . 35 To separate the engine and gearbox, first remove the starter motor. 36 Unbolt the flywheel front, lower and rear cover plates, then unscrew the four bolts securing the gearbox to the engine and gently prise the gearbox off the two locating dowels (at the front a[...]

similar small container (see illustration) . Note that No 1 valve is nearest to the timing belt end of the engine. 7 Cylinder head and valves - cleaning and inspection 4 Note: If the engine has been severely overheated, it is best to assume that the cylinder head is warped and to check carefully for signs of this. Note: Be sure to perform all the f[...]

even the renewal of the valve or seat insert is required. 14 Valve grinding is carried out as follows. Place the cylinder head upside down on a bench. 15 Smear a trace of (the appropriate grade of) valve-grinding compound on the seat face and press a suction grinding tool onto the valve head. With a semi-rotary action, grind the valve head to its s[...]

7 Remove the sump and unbolt the oil pump pick-up/strainer pipe from the oil rail. Discard the sealing ring (see illustration) . 8 Unscrew the two retaining nuts and remove the oil rail (see illustration) . 9 Using a hammer and centre punch, paint or similar, mark each connecting rod big-end bearing cap with its respective cylinder number on the fl[...]

push the connecting rod up and off the crankpin, ensuring that the connecting rod big-ends do not mark the cylinder bore walls, then remove the upper bearing shell. Keep the cap, bolts and (if they are to be refitted) the bearing shells together in their correct sequence. 11 With Nos 2 and 3 cylinder big-ends disconnected, repeat the procedure (exe[...]

10 Remove the crankshaft (see illustration) . 11 Withdraw the two thrustwashers from the No 3 main bearing upper location. Noting the position of the grooved shells, remove the upper main bearing shells, which must be kept with their correct respective partners from the main bearing ladder so that all shells can be identified and (if necessary) ref[...]

rings and to the liner surface on each side of the rings (see illustration) . 3 If the original liners are being refitted, use the marks made on removal to ensure that each is refitted the same way round into its original bore. Insert each liner into the cylinder block/crankcase, taking great care not to displace or damage the sealing rings, and pr[...]

bearing journals for uneven wear, scoring, pitting and cracking. 6 Rub a penny across each journal several times. If a journal picks up copper from the penny, it is too rough (see illustration) . 7 Remove any burrs from the crankshaft oil holes with a stone, file or scraper. 8 Using a micrometer, measure the diameter of the main bearing and crankpi[...]

16 Engine overhaul - reassembly sequence 1 Before reassembly begins, ensure that all new parts have been obtained and that all necessary tools are available. Read through the entire procedure to familiarise yourself with the work involved and to ensure that all items necessary for reassembly of the engine are at hand. In addition to all normal tool[...]

Main bearing running clearance check 7 Clean the backs of the bearing shells and the bearing locations in both the cylinder block/crankcase and the main bearing ladder. 8 Press the bearing shells into their locations, ensuring that the tab on each shell engages in the notch in the cylinder block/crankcase or main bearing ladder location. Take care [...]

assemblies (see illustrations) . Leave No 1 and 4 cylinders at the TDC position 25 Thoroughly degrease the mating surfaces of the cylinder block/crankcase and the main bearing ladder. Apply the special Rover sealant to the mating surface of the cylinder block/crankcase as shown (see illustration) . Carefully follow the instructions supplied with th[...]

33 Refit the dipstick tube to the cylinder block/crankcase, tightening the bolts to the specified torque wrench setting. 34 Refit the timing belt inner cover, the sprocket(s) and tensioner, and the belt itself. 35 Using a torque wrench, check that the amount of force required to rotate the crankshaft does not exceed 31 Nm. If the effort required is[...]

13 Lubricate the cylinder bores, the pistons and piston rings, then lay out each piston/connecting rod assembly in its respective position. 14 Starting with assembly No 1, make sure that the piston rings are still correctly spaced, then clamp them in position with a piston ring compressor. 15 Insert the piston/connecting rod assembly into the top o[...]

20 Engine - initial start-up after overhaul 2 1 With the engine refitted in the vehicle, double-check the engine oil and coolant levels. Make a final check that everything has been reconnected and that there are no tools or rags left in the engine compartment. 2 With the spark plugs removed and the ignition system disabled by earthing the ignition [...]