Rover 214 & 414 - Car-Repair Manual-Haynes.pdf

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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
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
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.
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Contents
LIVING WITH YOUR ROVER 214 & 414
Introduction
Page 0•4
Safety First!
Page 0•5
Roadside Repairs
Introduction
Page 0•6
If your car won’t start
Page 0•6
Jump starting
Page 0•7
Wheel changing
Page 0•8
Identifying leaks
Page 0•9
Towing
Page 0•9
Weekly Checks
Introduction
Page 0•10
Underbonnet check points
Page 0•10
Engine oil level
Page 0•11
Coolant level
Page 0•11
Brake fluid level
Page 0•12
Screen washer fluid level
Page 0•12
Power steering fluid level
Page 0•13
Wiper blades
Page 0•13
Tyre condition and pressure
Page 0•14
Electrical systems
Page 0•15
Battery
Page 0•15
Lubricants, Fluids, Capacities and Tyre Pressures
Page 0•16
MAINTENANCE
Routine Maintenance and Servicing
Page 1•1
Maintenance schedule
Page 1•3
Maintenance procedures
Page 1•6
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Contents
REPAIRS 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-point fuel injected engines
Page 4B•1
Fuel and exhaust systems - multi-point fuel injected engines
Page 4C•1
Emission control systems
Page 4D•1
Ignition system - carburettor engines
Page 5A•1
Ignition system - fuel injected engines
Page 5B•1
Starting and charging systems
Page 5C•1
Transmission
Clutch
Page 6•1
Gearbox
Page 7•1
Driveshafts
Page 8•1
Brakes and Suspension
Braking system
Page 9•1
Suspension and steering
Page 10•1
Body Equipment
Bodywork and fittings
Page 11•1
Body electrical systems
Page 12•1
Wiring Diagrams
Page 12•20
REFERENCE
Dimensions and Weights
Page REF•1
Conversion Factors
Page REF•2
Buying Spare Parts and Vehicle Identification
Page REF•3
General Repair Procedures
Page REF•4
Jacking and Vehicle Support
Page REF•5
Radio/cassette Anti-theft System - precaution
Page REF•5
Tools and Working Facilities
Page REF•6
MOT Test Checks
Page REF•8
Fault Finding
Page REF•12
Glossary of Technical Terms
Page REF•19
Index
Page REF•24
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0•4
Introduction
The Rover 214 Hatchback and 414 Saloon
models covered in this Manual are a much-
developed version of the original 213 and 216
models first launched in 1984. The 214 five-door
model was the first to be introduced in October
1989 and was closely followed by the
414 model introduced in March 1990. The 214
model range was further updated in September
1990 when a three-door variant was introduced.
All models are fitted with the new 1.4 litre
‘K’ series engine. The 214 S model (first
introduced in September 1990) has an eight-
valve single overhead camshaft version of the
engine which is fed by an SU KIF carburettor.
All other 214 and 414 models are equipped
with a sixteen-valve double overhead
camshaft version of the engine which is
controlled by a Rover/Motorola Modular
Engine Management System (MEMS) with
either single-point fuel injection (SPi) or multi-
point fuel injection (MPi). All versions of the
engine are able to accept a full range of
emission control systems, up to and including
a three-way regulated catalytic converter.
The five-speed transmission, which is a
joint development by Rover and Peugeot
engineers, is of Peugeot design and produced
by Rover. The transmission is fitted to the left-
hand end of the engine. The complete
engine/transmission unit is mounted
transversely across the front of the car and
drives the front wheels through unequal-
length driveshafts.
The front suspension incorporates
MacPherson struts and the rear is of the
double wishbone type.
Braking is by discs at the front and drums
at the rear, with a dual-circuit hydraulic
system. On all models in the range, an Anti-
lock Braking System (ABS) was offered as an
optional extra. If ABS is fitted, then braking is
by discs both at the front and rear.
Rover 114GTa
Rover Metro 1.1S
Your Rover 214 & 414 Manual
The aim of this manual is to help you get
the best value from your vehicle. It can do so
in several ways. It can help you decide what
work must be done (even should you choose
to get it done by a garage), provide
information on routine maintenance and
servicing, and give a logical course of action
and diagnosis when random faults occur.
However, it is hoped that you will use the
manual by tackling the work yourself. On
simpler jobs it may even be quicker than
booking the car into a garage and going there
twice, to leave and collect it. Perhaps most
important, a lot of money can be saved by
avoiding the costs a garage must charge to
cover its labour and overheads.
The manual has drawings and descriptions
to show the function of the various components
so that their layout can be understood. Then
the tasks are described and photographed in a
clear step-by-step sequence.
Acknowledgements
Thanks are due to Champion Spark Plug
who supplied the illustrations showing spark
plug conditions, and to Duckhams Oils who
provided lubrication data. Thanks are also
due to Sykes-Pickavant Limited, who
supplied some of the workshop tools, and to
all those people at Sparkford who helped in
the production of this Manual.
We take great pride in the accuracy of
information given in this manual, but
vehicle manufacturers make alterations
and design changes during the production
run of a particular vehicle of which they
do not inform us. No liability can be
accepted by the authors or publishers for
loss, damage or injury caused by any
errors in, or omissions from the
information given.
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Safety First!
0•5
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.
• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400 0 C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.
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