Land Rover Rover 214 Repair 1689 02b Rover Manual
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bearing journals for uneven wear, scoring, pitting and cracking. 6Rub a penny across each journal several times. If a journal picks up copper from the penny, it is too rough (see illustration). 7Remove any burrs from the crankshaft oil holes with a stone, file or scraper. 8Using a micrometer, measure the diameter of the main bearing and crankpin (big-end) journals and compare the results with those specified (see illustration). Check carefully that each journal’s diameter is within the tolerances of the size grade corresponding to the code number on the crankshaft right-hand web (main bearing) or indicated by the code letter on the left-hand web (crankpin/big-end bearing). If any diameter measured is incorrect for the grade indicated, re-check the measurement carefully. If the journal is fit for further service, the correct grade code should be substituted when selecting new bearing shells. 9By measuring the diameter at a number of points around each journal’s circumference,you will be able to determine whether or not the journal is out-of-round. Take the measurement at each end of the journal (near the webs) to determine if the journal is tapered. 10If the crankshaft journals are damaged, tapered, out-of-round or worn beyond the limits specified, the crankshaft must be renewed unless an engine overhaul specialist can be found who will regrind it and supply the necessary undersize bearing shells. 11Check the oil seal journals at each end of the crankshaft for wear and damage. If either seal has worn an excessive groove in its journal, consult an engine overhaul specialist who will be able to advise whether a repair is possible or whether a new crankshaft is necessary. 15 Main and big-end bearings- inspection 3 1Even though the main and big-end bearings should be renewed during the engine overhaul, the old bearings should be retained for close examination, as they may reveal valuable information about the condition of the engine. The bearing shells are graded by thickness, the grade of each shell being indicated by the colour code marked on it. 2Bearing failure occurs because of lack of lubrication, the presence of dirt or other foreign particles, overloading the engine and corrosion. Regardless of the cause of bearing failure, it must be corrected before the engine is reassembled to prevent it from happening again (see illustration). 3When examining the bearing shells, remove them from the cylinder block/crankcase, the main bearing ladder, the connecting rods and the connecting rod big-end bearing caps, then lay them out on a clean surface in the same general position as their location in the engine. This will enable you to match any bearing problems with the corresponding crankshaft journal. Do not touch any shell’sbearing surface with your fingers while checking it, or the delicate surface may be scratched. 4Dirt and other foreign particles get into the engine in a variety of ways. It may be left in the engine during assembly, or it may pass through filters or the crankcase ventilation system. It may get into the oil and from there into the bearings. Metal chips from machining operations and normal engine wear are often present. Abrasives are sometimes left in engine components after reconditioning, especially when parts are not thoroughly cleaned by using the proper cleaning methods. Whatever the source, these foreign objects often end up embedded in the soft bearing material and are easily recognized. Large particles will not embed in the bearing but will score or gouge the bearing and journal. The best prevention for this cause of bearing failure is to clean all parts thoroughly and keep everything spotlessly clean during engine assembly. Frequent and regular engine oil and filter changes are also recommended. 5Lack of lubrication (or lubrication breakdown) has a number of interrelated causes. Excessive heat (which thins the oil), overloading (which squeezes the oil from the bearing face) and oil leakage (from excessive bearing clearances, worn oil pump or high engine speeds) all contribute to lubrication breakdown. Blocked oil passages, which usually are the result of misaligned oil holes in a bearing shell, will also oil starve a bearing and destroy it. When lack of lubrication is the cause of bearing failure, the bearing material is wiped or extruded from the steel backing of the bearing. Temperatures may increase to the point where the steel backing turns blue from overheating. 6Driving habits can have a definite effect on bearing life. Full throttle, low speed operation (labouring the engine) puts very high loads on bearings, which tends to squeeze out the oil film. These loads cause the bearings to flex, which produces fine cracks in the bearing face (fatigue failure). Eventually, the bearing material will loosen in pieces and tear away from the steel backing. Short-distance driving leads to corrosion of bearings because insufficient engine heat is produced to drive off the condensed water and corrosive gases. These products collect in the engine oil, forming acid and sludge. As the oil is carried to the engine bearings, the acid attacks and corrodes the bearing material. 7Incorrect bearing installation during engine assembly will lead to bearing failure as well. Tight fitting bearings leave insufficient bearing running clearance and will result in oil starvation. Dirt or foreign particles trapped behind a bearing shell result in high spots on the bearing which lead to failure. Do not touch any shell’s bearing surface with your fingers during reassembly as there is a risk of scratching the delicate surface or of depositing particles of dirt on it. Engine removal and general overhaul procedures 2B•11 15.2 Typical bearing shell failures 14.8 Measuring crankshaft journal diameter14.6 Using a penny to check crankshaft journal condition 2B 1689 Rover 214 & 414 Updated Version 09/97
16 Engine overhaul- reassembly sequence 1Before 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 tools and materials, it will be necessary to obtain the Rover sealant kit LVV 10002. Carefully read the instructions supplied with the sealant kit and take care not to allow the sealant to contact the fingers, as it will bond skin. 2In order to save time and avoid problems, engine reassembly can be carried out in the following order: a) Crankshaft. b) Piston/connecting rod assemblies. c) Oil pump. d) Sump. e) Flywheel. f) Cylinder head. g) Timing belt inner cover, tensioner and sprockets, and timing belt. h) Engine external components. 3At this stage, all engine components should be absolutely clean and dry, with all faultsrepaired, and should be laid out (or in individual containers) on a completely clean work surface.17 Piston rings- refitting 3 1Refer to Section 13 for inspection details. 2Once all rings have been checked, they can be installed. Ensure that each ring is refitted only to its matched piston and bore. 3Install the new rings by fitting them over the top of the piston, starting with the oil control ring spring. Note that all rings must be fitted with the word TOP uppermost (see illustration). 4With all the rings in position, space the ring gaps as shown (see illustration), noting that the FRONT marking shown is usually in fact an arrow mark on the piston crown and indicates the timing belt end of the engine. 18 Crankshaft- refitting and main bearing running clearance check 4 Selection of bearing shells 1The main bearing running clearance is controlled in production by selecting one of three grades of bearing shell. The grades are indicated by a colour-coding marked on the edge of each shell which governs the shell’s thickness, as follows: a) Green - Thin. b) Blue - Intermediate. c) Red - Thick.2If shells of differing grades are to be fitted to the same journal, the thicker shell must always be fitted to the main bearing ladder location. Bear this carefully in mind when ordering replacement shells for Nos 2, 3 and 4 bearings. 3If the bearing shells are to be renewed, first check and record the main bearing code letters stamped on the right-hand front face of the main bearing ladder (see illustration). The letters are read with the ladder inverted, No 1 bearing’s code letter then being at the top and the remainder following in order from the engine’s timing belt end. 4Secondly, check and record the crankshaft journal code numbers stamped on the crankshaft’s right-hand web, No 1 journal’s code number being the first. If the original crankshaft is to be re-used, the size grade can be checked by direct measurement, as described in Section 14. 5Note that if the crankshaft is found to be excessively worn, then it must be renewed and the code numbers of the new component must be used instead to select a new set of bearing shells. 6Matching the codes noted to the following table, select a new set of bearing shells. Ladder code Crankshaft letter code number Shells A 1 Blue, Blue A 2 Red, Blue A 3 Red, Red B 1 Blue, Green B 2 Blue, Blue B 3 Red, Blue C 1 Green, Green C 2 Blue, Green C 3 Blue, Blue 2B•12 Engine removal and general overhaul procedures 18.3 Crankshaft main bearing size code locations 17.4 Piston ring end gap locations A Top compression ring B Second compression ring C Oil control ring D Oil control ring spring 17.3 Piston ring fitting details and top surface markings 1689 Rover 214 & 414 Updated Version 09/97
Main bearing running clearance check 7Clean the backs of the bearing shells and the bearing locations in both the cylinder block/crankcase and the main bearing ladder. 8Press 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 not to touch any shell bearing surface with your fingers. 9Press the bearing shells with the oil grooves into the upper locations (in the cylinder block/crankcase). Note the following points (see illustration): a) On all engines, grooved bearing shells are fitted to Nos 2, 3 and 4 upper bearing locations. Note the central locating tabs of the grooved shells. b) On early engines, grooved bearing shells were fitted only to Nos 2 and 4 upper bearing locations at the factory. On reassembly of one of these units, a grooved shell must be fitted at No 3 upper bearing location as well, instead of the plain item originally used. Note, however, that this will require a grooved shell with an offset locating tab instead of the central tab that is used on all other grooved shells. See your Rover dealer for details. c) If bearing shells of differing grades are to be fitted to the same journal, the thicker shell must always be fitted to the main bearing ladder location (see paragraph 1). d) On all engines, if the original main bearing shells are being re-used, these must be refitted to their original locations in the cylinder block/crankcase and main bearing ladder. 10The main bearing running clearance should be checked if there is any doubt about the amount of crankshaft wear that has taken place, if the crankshaft has been reground and is to be refitted with non-Rover undersized bearing shells, or if non-genuinebearing shells are to be fitted. If the original crankshaft or a Rover replacement part is to be installed, the shell selection procedure given above will produce the correct clearances and a further check will not be necessary. If the clearance is to be checked, it can be done in either of two ways. 11The first method (which will be difficult to achieve without a range of internal micrometers or internal/external expanding calipers) is to refit the main bearing ladder to the cylinder block/crankcase, with bearing shells in place. With the ladder retaining bolts tightened to the specified torque, refit the oil rail and the cylinder head, then measure the internal diameter of each assembled pair of bearing shells. If the diameter of each corresponding crankshaft journal is measured and then subtracted from the bearing internal diameter, the result will be the main bearing running clearance. 12The second (and more accurate) method is to use product known as Plastigauge. This consists of a fine thread of perfectly round plastic which is compressed between the bearing shell and the journal. When the shell is removed, the plastic is deformed and can be measured with a special card gauge supplied with the kit. The running clearance is determined from this gauge. Plastigauge is sometimes difficult to obtain but enquiries at one of the larger specialist quality motor factors should produce the name of a stockist in your area. The procedure for using Plastigauge is as follows. 13With the main bearing upper shells in place, carefully lay the crankshaft in position. Do not use any lubricant. The crankshaft journals and bearing shells must be perfectly clean and dry. 14Cut several lengths of the appropriate size Plastigauge (they should be slightly shorter than the width of the main bearings) and place one length on each crankshaft journal axis (see illustration). 15With the main bearing lower shells in position, refit the main bearing ladder (see below) and the oil rail, tightening the fastenersto the specified torque wrench settings. Take care not to disturb the Plastigauge. 16Refit the cylinder head (using the original gasket, to save over-compressing the new one). Tighten the bolts to the specified torque in the approved sequence. Do notrotate the crankshaft at any time during this operation. 17Remove the cylinder head, the oil rail and the main bearing ladder. Do not disturb the Plastigauge or rotate the crankshaft. 18Compare the width of the crushed Plastigauge on each journal to the scale printed on the Plastigauge envelope to obtain the main bearing running clearance (see illustration). 19If the clearance is not as specified, the bearing shells may be the wrong grade (or excessively worn if the original shells are being re-used). Before deciding that different grade shells are needed, make sure that no dirt or oil was trapped between the bearing shells and the ladder or cylinder block/crankcase when the clearance was measured. If the Plastigauge was wider at one end than at the other, the journal may be tapered. 20Carefully scrape away all traces of the Plastigauge material from the crankshaft and bearing shells using a fingernail or other object which is unlikely to score the shells. Final crankshaft refitting 21Carefully lift the crankshaft out of the cylinder block once more. 22Using a little grease, stick the thrustwashers to each side of the No 3 main bearing upper location. Ensure that the oilway grooves on each thrustwasher face outwards. 23Place the bearing shells in their locations, as described in paragraphs 7 to 9. If new shells are being fitted, ensure that all traces of the protective grease are cleaned off using paraffin. Wipe dry the shells and connecting rods with a lint-free cloth. Liberally lubricate each bearing shell in the cylinder block/crankcase, then lower the crankshaft into position so that Nos 2 and 3 cylinder crankpins are at TDC. 24Refit the piston/connecting rod Engine removal and general overhaul procedures 2B•13 18.18 Using scale on Plastigauge envelope to check (at widest point) width of crushed Plastigauge18.14 Lay length of Plastigauge on journal to be measured, parallel to crankshaft centre-line18.9 Ensure grooved bearing shells (arrowed) are installed exactly as described in text - early engine shown 2B 1689 Rover 214 & 414 Updated Version 09/97
assemblies (see illustrations). Leave No 1 and 4 cylinders at the TDC position 25Thoroughly 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 the sealant kit. If the Rover sealant is being used, assembly must be completed as soon as possible after the sealant has been applied (maximum of 20 minutes). If another sealant is being used, follow the manufacturer’s instructions.26Lubricate the bearing shells, then refit the main bearing ladder, ensuring that the shells are not displaced and that the locating dowels engage correctly. Working progressively, by a turn at a time and in the sequence shown (see illustration), tighten the ladder bolts to the specified torque wrench setting. The crankshaft cannot now be rotated. 27Thoroughly degrease the mating surfaces of the oil rail and the main bearing ladder. Apply the special Rover sealant to the oil rail mating surface as shown (see illustration). Carefully follow the instructions supplied with the sealant kit.28Refit the oil rail, tightening the nuts to the specified torque wrench setting. 29Using a new sealing ring, refit the oil pump pick-up/strainer pipe to the oil rail, then refit the sump. Tighten all nuts and bolts to the specified torque wrench settings. 30Fit a new crankshaft left-hand oil seal, then refit the flywheel(see illustrations). 31Refit the oil pump and install a new crankshaft right-hand oil seal(see illustrations). 32Refit the cylinder head. Rotate the crankshaft to the 90° BTDC position so that the crankshaft sprocket timing marks align. 2B•14 Engine removal and general overhaul procedures 18.31a Use grease to stick new gasket in place when refitting oil pump18.30c Use fabricated tool to lock flywheel while slackening or tightening flywheel bolts18.30b Always use new bolts when refitting flywheel 18.30a Fitting a new crankshaft left-hand oil seal18.27 Apply thin bead of sealant to oil rail mating surface as shown by heavy black lines, then spread to an even film18.26 Crankshaft main bearing ladder bolt tightening sequence 18.25 Apply thin bead of sealant to cylinder block/crankcase mating surface along paths shown by heavy black lines, then spread to an even film18.24b . . . care is required to hold crankshaft steady while connecting rod big-end cap bolts are tightened18.24a If piston/connecting rod assemblies are refitted before main bearing ladder . . . 1689 Rover 214 & 414 Updated Version 09/97
33Refit the dipstick tube to the cylinder block/crankcase, tightening the bolts to the specified torque wrench setting. 34Refit the timing belt inner cover, the sprocket(s) and tensioner, and the belt itself. 35Using a torque wrench, check that the amount of force required to rotate the crankshaft does not exceed 31 Nm. If the effort required is greater than this, the engine must be dismantled again to trace and rectify the cause. This value takes into account the increased friction of a new engine and is much higher than the actual pressure required to rotate a run-in engine, so do not make allowances for tight components. 19 Piston/connecting rod assembly- refitting and big-end bearing running clearance check 4 Selection of bearing shells 1The big-end bearing running clearance is controlled in production by selecting one of three grades of bearing shell. The grades are indicated by a colour-coding marked on the edge of each shell which governs the shell’s thickness, as follows: a) Yellow - Thin. b) Blue - Intermediate. c) Red - Thick. 2If shells of differing grades are to be fitted to the same journal, the thicker shell must always be fitted to the big-end bearing cap location. 3If the bearing shells are to be renewed, first check and record the codes stamped on the front face of each big-end bearing cap and connecting rod. The number stamped on the big-end bearing cap is the bearing size code, the number stamped on the connecting rod is the piston/rod assembly’s cylinder number and the letter stamped on the connecting rod is the weight code (see illustration). 4Secondly, check and record the crankpin/big-end journal code letters stamped on the crankshaft’s left-hand web (see illustration), No 1 journal’s code letterbeing the first. If the original crankshaft is to be re-used, the code letter can be checked by direct measurement. 5If the crankshaft is found to be excessively worn, then it must be renewed and the code letters of the new component must be used instead to select a new set of bearing shells. 6Matching the codes noted to the following table, select a new set of bearing shells: Cap code Crankshaft number code letter Shells 5 A Blue, Blue 5 B Red, Blue 5 C Red, Red 6 A Blue, Yellow 6 B Blue, Blue 6 C Red, Blue 7 A Yellow, Yellow 7 B Blue, Yellow 7 C Blue, Blue Big-end bearing running clearance check 7The big-end bearing running clearance should be checked if there is any doubt about the amount of crankshaft wear that has taken place, if the crankshaft has been reground and is to be refitted with non-Rover undersized bearing shells, or if non-genuine bearing shells are to be fitted. If the original crankshaft or a Rover replacement part is to be installed, the shell selection procedure given above will produce the correct clearances and a further check will not be necessary. If the clearance is to be checked, it can be done in either of two ways. 8The first method is to refit the big-end bearing cap to the connecting rod, with bearing shells in place. With the cap retaining bolts tightened to the specified torque, use an internal micrometer or vernier caliper to measure the internal diameter of each assembled pair of bearing shells. If the diameter of each corresponding crankshaft journal is measured and then subtracted from the bearing internal diameter, the result will be the big-end bearing running clearance. 9The second method is to use Plastigauge. Place a strand of Plastigauge on each(cleaned) crankpin journal and refit the (clean) piston/connecting rod assemblies, shells and big-end bearing caps, tightening the bolts to the specified torque wrench settings. Take care not to disturb the Plastigauge. Dismantle the assemblies without rotating the crankshaft and use the scale printed on the Plastigauge envelope to obtain the big-end bearing running clearance. On completion of the measurement, carefully scrape off all traces of Plastigauge from the journal and shells using a fingernail or other object which will not score the components. Final piston/connecting rod assembly refitting 10Note that the following procedure assumes that the cylinder liners have been refitted to the cylinder block/crankcase and that the crankshaft and main bearing ladder are in place. It is of course possible to refit the piston/connecting rod assemblies to the cylinder bores, to refit the crankshaft and to reassemble the piston/connecting rods on the crankshaft before refitting the main bearing ladder (see Section 18). 11Clean the backs of the bearing shells and the bearing recesses in both the connecting rod and the big-end bearing cap. If new shells are being fitted, ensure that all traces of the protective grease are cleaned off using paraffin. Wipe dry the shells and connecting rods with a lint-free cloth. 12Press the bearing shells into their locations, ensuring that the tab on each shell engages in the notch in the connecting rod or big-end bearing cap and taking care not to touch any shell’s bearing surface with your fingers. Note the following points: a) If bearing shells of differing grades are to be fitted to the same journal, the thicker shell must always be fitted to the big-end bearing cap location (see paragraph 1). b) On all engines, if the original big-end bearing shells are being re-used, these must be refitted to their original locations in the connecting rod and big-end bearing cap. Engine removal and general overhaul procedures 2B•15 19.4 Crankpin (big-end) journal size code location 19.3 Big-end bearing size code number (A - on cap) piston/connecting rod assembly cylinder number (B) and connecting rod weight code letter (C)18.31b Fitting a new crankshaft right-hand oil seal 2B 1689 Rover 214 & 414 Updated Version 09/97
13Lubricate the cylinder bores, the pistons and piston rings, then lay out each piston/connecting rod assembly in its respective position. 14Starting with assembly No 1, make sure that the piston rings are still correctly spaced, then clamp them in position with a piston ring compressor. 15Insert the piston/connecting rod assembly into the top of liner No 1, ensuring that the arrow (or FRONT marking) on the piston crown faces the timing belt end of the engine. Note that the stamped marks on the connecting rod and big-end bearing cap should face the front (alternator bracket side) of the engine. Using a block of wood or hammer handle against the piston crown, tap the assembly into the liner until the piston crown is flush with the top of the liner (see illustrations). 16Ensure that the bearing shell is still correctly installed. Taking care not to mark the liner bores, liberally lubricate the crankpin andboth bearing shells, then pull the piston/connecting rod assembly down the bore and onto the crankpin. Noting that the faces with the stamped marks must match (which means that the bearing shell locating tabs abut each other), refit the big-end bearing cap, tightening the bolts finger-tight at first. 17Use a torque wrench to tighten the bolts evenly to the (first stage) torque wrench setting specified, then use an angular torque gauge to tighten the bolts evenly through the (second stage) angle specified (see illustrations). 18Repeat the procedure for the remaining three piston/connecting rod assemblies, but do not attempt to rotate the crankshaft. 19Thoroughly degrease the mating surfaces of the oil rail and the main bearing ladder. Apply the special Rover sealant to the oil rail mating surface (see illustration 18.27). Carefully follow the instructions supplied with the sealant kit.20Refit the oil rail, tightening the nuts to the specified torque wrench setting. 21Refit the oil pump pick-up/strainer pipe and sump. 22Refit the cylinder head. Rotate the crankshaft to the 90° BTDC position so that the crankshaft sprocket timing marks align. 23Refit the dipstick tube to the cylinder block/crankcase, tightening the bolts to the specified torque wrench setting. 24Refit the hydraulic tappets and camshaft(s). 25Refit the timing belt inner cover, sprocket(s) and tensioner, and the belt itself. 26Using a torque wrench, check that the amount of force required to rotate the crankshaft does not exceed 31 Nm. If the effort required is greater than this, the engine must be dismantled again to trace and rectify the cause. This value takes into account the increased friction of a new engine and is much higher than the actual pressure required to rotate a run-in engine, so do not make allowances for tight components. 2B•16 Engine removal and general overhaul procedures 19.17b . . . then use angular torque gauge to tighten bolts through angle specified (second stage)19.17a Tighten connecting rod big-end bearing cap bolts to specified torque wrench setting (first stage) . . . 18.15b Using piston ring compressor to clamp piston rings19.15a Arrow or FRONT marking (arrowed) on piston crown must point to timing belt end of engine 1689 Rover 214 & 414 Updated Version 09/97
20 Engine- initial start-up after overhaul 2 1With 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. 2With the spark plugs removed and the ignition system disabled by earthing the ignition HT coil distributor spark plug (HT) lead with a jumper lead, turn the engine over on the starter until the oil pressure warning lamp goes out.3Refit the spark plugs and connect all the spark plug (HT) leads. 4Start the engine, noting that this may take a little longer than usual due to the fuel system components being empty. 5While the engine is idling, check for fuel, coolant and oil leaks. Do not be alarmed if there are some odd smells and smoke from parts getting hot and burning off oil deposits. If the hydraulic tappets have been disturbed, some valve gear noise may be heard at first; this should disappear as the oil circulates fully around the engine and normal pressure is restored in the tappets. 6Keep the engine idling until hot coolant isfelt circulating through the top hose, check the ignition timing and idle speed and mixture (as appropriate), then switch it off. 7After a few minutes, recheck the oil and coolant levels and top up as necessary. 8If they were tightened as described, there is no need to re-tighten the cylinder head bolts once the engine has first run after reassembly. 9If new pistons, rings or crankshaft bearings have been fitted, the engine must be run-in for the first 500 miles (800 km). Do not operate the engine at full throttle or allow it to labour in any gear during this period. It is recommended that the oil and filter be changed at the end of this period. Engine removal and general overhaul procedures 2B•17 2B 1689 Rover 214 & 414 Updated Version 09/97