Land Rover Rover 214 Repair 1689 05a Rover Manual
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1689 Rover 214 & 414 Updated Version 09/97 5A Chapter 5 Part A Ignition system - carburettor engines Distributor - removal, overhaul and refitting . . . . . . . . . . . . . . . . . . . 5 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1 HT coil - removal, testing and refitting . . . . . . . . . . . . . . . . . . . . . . . 4 HT leads, distributor cap and rotor arm - inspection and renewal . . 3 Ignition amplifier module - removal and refitting . . . . . . . . . . . . . . . . 6Ignition system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ignition timing - checking and adjustment . . . . . . . . . . . . . . . . . . . . 8 Spark plugs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thermostatically-operated vacuum switch - removal and refitting . . 7 5A•1 Contents Specifications General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas constant energy inductive Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end) Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (viewed from right-hand side of vehicle) Distributor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas 67 DM4, incorporating centrifugal and vacuum advance mechanisms and externally-mounted amplifier module Identification: With catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NJC 10026 Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NJC 10033 Direction of rotor arm rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-clockwise (viewed from left-hand side of vehicle) Pick-up coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 to 1150 ohms Vacuum diaphragm unit identification: With catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-8 Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-6 Vacuum advance commences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 mbar (80 mm Hg) Maximum vacuum advance: With catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16º @ 267 mbar (200 mm Hg) Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12º @ 267 mbar (200 mm Hg) Deceleration check - vacuum disconnected . . . . . . . . . . . . . . . . . . . . . 4º to 8º @ 2500 rpm Note:Degree and speed values to be measured at crankshaft HT coil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUU 1326 or ADU 8779 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch, Ducellier or Rudi Cajavec Current consumption - average . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.75 amps @ idle speed Winding resistances: Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 0.5 ohms @ 20ºC Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 15 K ohms @ 20ºC Ignition timing At 1500 rpm (vacuum pipe disconnected) . . . . . . . . . . . . . . . . . . . . . . . 9º ± 1º BTDC Easy,suitable for novice with little experienceFairly easy,suitable for beginner with some experienceFairly difficult, suitable for competent DIY mechanic Difficult,suitable for experienced DIY mechanicVery difficult, suitable for expert DIY or professional Degrees of difficulty 54321
Torque wrench settingsNm lbf ft Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Distributor cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 21 Amplifier module-to-distributor body (hex-head) screws . . . . . . . . . . . . 5 4 Distributor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Ignition HT coil mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 5A•2 Ignition system - carburettor engines 1689 Rover 214 & 414 Updated Version 09/97 1 General information and precautions General information The ignition system is fully-electronic in operation and of the inductive type, incorporating a contact-less distributor (driven off the camshaft left-hand end) and an amplifier module, as well as the spark plugs, HT leads, ignition HT coil and associated wiring. The system is divided into two circuits, which are the primary (low tension/LT) and secondary (high tension/HT). The primary circuit consists of the battery, ignition switch, ignition HT coil primary windings, amplifier module and distributor pick-up coil and wiring. The secondary circuit consists of the ignition HT coil secondary windings, the distributor cap and rotor arm, the spark plugs and HT leads. The distributor incorporates features which advance the ignition timing both mechanically and by vacuum operation. Its shaft, driven by the camshaft, incorporates a reluctor which has four shaped poles and is mounted on the centre of a centrifugal advance assembly, whose two weights move outwards under centrifugal force as engine speed rises, thus rotating the reluctor on the shaft and advancing or retarding the spark, the amount of movement being controlled by light springs. A pick-up coil generates a weak magnetic field whenever the ignition is switched on. As the engine rotates the reluctor poles pass the coil, disturbing the field each time and sending a signal current to the amplifier module. Whenever this signal exceeds a threshold level determined by engine speed, a high-voltage transistor in the amplifier is switched on, thus allowing HT coil current to flow. When this current has reached the required level, it is held constant until the transistor is switched off, thus triggering the spark. The pick-up coil is clamped to a stator pack that is able to rotate under the control of the vacuum diaphragm unit mounted on the side of the distributor. The unit consists of a diaphragm, one side of which is connected via a small-bore pipe to the carburettor and the other side to the stator pack. Inlet manifold depression, which varies with engine speed and throttle position, causes the diaphragm to move, thus rotating the stator pack and advancing or retarding the spark. Models fitted with catalytic converters have a thermostatically-operated vacuum switchscrewed into the cooling system thermostat housing. The switch is connected into the vacuum hose linking the carburettor to the distributor vacuum diaphragm unit. At coolant temperatures below 70ºC, the switch cuts off the vacuum supply to the diaphragm and prevents the unit from advancing the ignition timing. This causes the exhaust gas temperatures to rise, due to the retarded ignition timing, and brings the catalytic converter swiftly up to its efficient operating temperature. Once coolant temperature rises above 70ºC, the switch opens and allows the vacuum to reach the diaphragm unit, thus restoring normal advance and retard of the ignition timing. Precautions General It is necessary to take extra care when working on the electrical system to avoid damage to semi-conductor devices (diodes and transistors), and to avoid the risk of personal injury. In addition to the precautions given in the “Safety first!” Section at the beginning of this manual, take note of the following points when working on the system. Always remove rings, watches, etc. before working on the electrical system. Even with the battery disconnected, capacitive discharge could occur if a component live terminal is earthed through a metal object. This could cause a shock or nasty burn. Do not reverse the battery connections. Components such as the alternator or any other having semi-conductor circuitry could be irreparably damaged. If the engine is being started using jump leads and a slave battery, connect the batteries positive to positive and negative to negative. This also applies when connecting a battery charger. Never disconnect the battery terminals, or alternator multi-plug connector, when the engine is running. The battery leads and alternator multi-plug must be disconnected before carrying out any electric welding on the car. Never use an ohmmeter of the type incorporating a hand cranked generator for circuit or continuity testing. Ignition and engine management systems The HT voltage generated by an electronic ignition system is extremely high, and in certain circumstances could prove fatal. Take care to avoid receiving electric shocks from the HT side of the ignition system. Personswith surgically-implanted cardiac pacemaker devices should keep well clear of the ignition circuits, components and test equipment. Do not handle HT leads, or touch the distributor or coil when the engine is running. If tracing faults in the HT circuit, use well insulated tools to manipulate live leads. Engine management modules are very sensitive components. Certain precautions must be taken to avoid damage to the module when working on a vehicle equipped with an engine management system, as follows. When carrying out welding operations on the vehicle using electric welding equipment, the battery and alternator should be disconnected. Although underbonnet-mounted modules will tolerate normal underbonnet conditions, they can be adversely affected by excess heat or moisture. If using welding equipment or pressure washing equipment in the vicinity of the module, take care not to direct heat, or jets of water or steam at the module. If this cannot be avoided, remove the module from the vehicle, and protect its wiring plug with a plastic bag. Before disconnecting any wiring, or removing components, always ensure that the ignition is switched off. On models with underbonnet-mounted modules, do not run the engine with the module detached from the body panel, as the body acts as an effective heat sink and the module may be damaged due to internal overheating. Do not attempt to improvise fault diagnosis procedures using a test lamp or multimeter, as irreparable damage could be caused to the module. After working on ignition/engine management system components, ensure that all wiring is correctly reconnected before reconnecting the battery or switching on the ignition. 2 Spark plugs- renewal Refer to Chapter 1. 3 HT leads, distributor cap and rotor arm- inspection and renewal Refer to Chapter 1.
4 HT coil- removal, testing and refitting 2 Removal 1The coil is mounted on the left-hand side of the engine compartment, between the battery and the left-hand headlamp unit. 2Disconnect the battery negative terminal. 3To improve access to the coil, remove the headlamp bulb cover. 4Peel back the end cover, then disconnect the HT lead from the coil. Note which terminals they are connected to and disconnect the two pairs of LT wires from the coil (see illustration). 5Remove the two coil mounting bolts and withdraw the coil from the engine compartment. If necessary, slacken the clamp screw and separate the coil from its mounting bracket. Testing 6Test the coil by using a multimeter, set to its resistance function, to check the primary (LT + to – terminals) and secondary (LT + to HTlead terminal) windings for continuity. The resistance of either winding can be checked and compared with the specified value. Note that the resistance of the coil windings will vary slightly according to the coil temperature. 7Using an ohmmeter or continuity tester, check that there is no continuity between the HT lead terminal and the coil body. 8If the coil is faulty it must be renewed. Refitting 9Refitting is the reverse of the removal procedure. 5 Distributor- removal, overhaul and refitting 3 Removal 1Disconnect the battery negative terminal. 2Release the wire retaining clip and unplug the wiring connector from the ignition amplifier module (see illustration). 3Disconnect the vacuum pipe from the vacuum diaphragm unit (see illustration). 4Position the engine so that No 1 cylinder is at TDC on the compression stroke. 5Mark the relationship of the distributor bodyto the cylinder head, as a guide for refitting (see illustration). 6Unscrew the distributor mounting bolts and withdraw the distributor (see illustration). Do not disturb the crankshaft setting while the distributor is removed. 7Remove the distributor body sealing ring which must be renewed whenever it is disturbed (see illustration). Overhaul 8Remove the distributor cap and withdraw the rotor arm, if not already removed (see illustration). Ignition system - carburettor engines 5A•3 5.3 Disconnecting vacuum pipe from distributor vacuum diaphragm unit5.2 Disconnecting wiring connector from ignition amplifier module4.4 HT coil connections 3 Mounting bolts 6 LT connections 4 Clamp screw 7 HT connection 5 HT coil 5.5 Making alignment marks on distributor body and cylinder head 5.7 . . . then remove distributor (O-ring arrowed)5.6 Unscrew distributor mounting bolts (remaining bolt arrowed) . . . 5A 1689 Rover 214 & 414 Updated Version 09/97
9Undo the two bolts securing the amplifier module to the body, then carefully remove the gasket and withdraw the connector. 10Remove the screws and separate the upper housing from the lower. 11Remove the clamp ring and pick-up coil from the upper housing.12Remove the circlip (and first thrustwasher, if fitted) from the underside of the upper housing, disengage the stator pack from the vacuum diaphragm unit arm and withdraw the stator pack, followed by the (second) thrustwasher. 13Remove the retaining screw and withdraw the vacuum diaphragm unit from the distributor. 14Check the distributor shaft endfloat and if it seems excessive, seek expert advice. 15Remove the spring from the distributor drive coupling, then use a scriber or similar to mark the relationship of the coupling to the shaft. It is essential that the coupling is refitted correctly in relationship to the rotor arm on refitting. Release the distributor shaft by driving out the retaining roll pin and removing the coupling, noting the toothed thrustwasher which is fitted behind it. 16Withdraw the shaft, noting the toothed thrustwasher underneath the centrifugal advance assembly. Be very careful not to bend any of the reluctor poles and do not attempt to remove it from the shaft. 17The advance assembly and shaft can be lubricated but if any part of the assembly is found to be worn or damaged, then the complete distributor must be renewed. Individual replacement parts are not available. 18Clean and examine all components. If any are found to be worn or damaged, seek expert advice. A repair kit of sundry parts is available separately, also the coupling assembly, the pick-up coil and vacuum diaphragm unit, as well as the rotor arm and the distributor cap. If any other parts are worn or damaged, the complete distributor must be renewed. 19In addition to the checks in Chapter 1, use an ohmmeter or continuity tester to check that there is no continuity between any of the cap’s terminal segments. Similarly, check that there is no continuity between the rotor arm body and its brass segment. Note that the arm has a built-in resistance. 20Reassembly is the reverse of the dismantling procedure, noting the following: a) Apply a few drops of suitable oil to the advance assembly pivots and springs, also to the shaft, upper housing and stator pack bearing surfaces. b) Using the marks made on dismantling, be very careful to ensure that the coupling is located correctly on the shaft end (in relationship to the rotor arm) before driving in the roll pin to secure it, then ensure that the spring is fitted over the roll pin ends. c) Grease the vacuum diaphragm unit arm before refitting it and use grease to stick the thrustwasher to the underside of the upper housing. Refit the stator pack, ensuring it engages correctly with the vacuum diaphragm unit arm peg, followed by the (remaining thrustwasher, if fitted, and) circlip. Tighten the unit retaining screw securely.d) Refit the pick-up coil to the upper housing and centre its terminals in the aperture before fitting the clamp ring so that its cut-out is over the aperture. e) Refit the upper housing to the lower, tighten the screws lightly and check that the shaft is free to rotate. There must be no sign of the reluctor poles touching the stator pack arms, as either can easily be bent. Tighten the screws securely. f) Refit the connector and its gasket. g) Refit the amplifier module and the rotor arm. h) Fit a new sealing ring to the distributor body. Refitting Original distributor 21Ensure that No 1 cylinder is at TDC, then rotate the rotor arm to align with the distributor cap’s No 1 terminal. Fit a new sealing ring to the distributor body and lubricate it with a smear of engine oil. 22Align the marks made on removal and refit the distributor to the cylinder head. If necessary, rotate the rotor arm very slightly to help the distributor drive dogs locate in the camshaft slots; they are offset and so will fit only one way. Refit the distributor mounting bolts and tighten them to the specified torque. 23Refit the spark plugs. 24Refit the distributor cap, ensuring it is correctly located, and tighten its retaining screws to the specified torque. Reconnect the HT leads to the relevant spark plugs. 25Reconnect the vacuum pipe to the vacuum diaphragm unit and the wiring connector to the ignition amplifier module. 26Check and, if necessary, adjust the ignition timing. New distributor 27If a new distributor is to be fitted (or no marks were made on removal), the following procedure will produce a basic setting which will enable the engine to start and run while the ignition timing is accurately set. 28Position the engine so that No 1 cylinder is at TDC on the compression stroke. 29Rotate the crankshaft slightly anti- clockwise until the pulley notch is positioned in the 9º BTDC position (between the 8 and 12 marks on the timing scale). 30Rotate the distributor rotor arm to align with the distributor cap’s No 1 terminal. This terminal is marked with a K which is cast on the outside of the distributor cap. Fit a new sealing ring to the distributor body and lubricate it with a smear of engine oil. 31Fit the distributor to the cylinder head and refit its mounting bolts. Positioning the distributor body so that the mounting bolts are in the middle of their respective slots then tighten the bolts finger-tight only. 32Perform the operations given in paragraphs 23 to 25. 33Check and adjust the ignition timing. 5A•4 Ignition system - carburettor engines 5.8 Lucas 67 DM4 distributor 1 Distributor cap 2 Rotor arm 3 Upper housing 4 Vacuum diaphragm unit 5 Stator pack including thrustwasher(s) and circlip 6 Pick-up coil 7 Clamp ring 8 Distributor shaft, including reluctor and advance assembly 9 Thrustwasher 10 Lower housing 11 O-ring 12 Drive coupling, including thrustwasher, spring and roll pin 13 Connector and gasket 14 Amplifier module 1689 Rover 214 & 414 Updated Version 09/97
6 Ignition amplifier module- removal and refitting 2 Warning: Do not attempt to open or repair the ignition amplifier module. If faulty, it must be renewed. Removal 1Disconnect the battery negative terminal. 2Releasing its wire clip, unplug the wiring connector from the amplifier module. 3Remove the two bolts and withdraw the module, taking care not to damage the terminal pins. 4Check carefully that the mating surfaces of the module and distributor are completely clean and unmarked and that the pick-up coil terminal pins are clean and a secure fit in the module. If in doubt, it is permissible to remove the connector and its gasket and to gently squeeze together the female terminals to improve the fit. 5The pick-up coil-to-connector and connector-to-module connections must be checked with particular care if the module is thought to be faulty. Similarly, check, clean and tighten (if necessary) the distributor wiring connector-to-module terminals. It is essential that there is good electrical contact between the module and the distributor and at all four LT wiring connections mentioned above. Refitting 6On refitting, apply a smear of heat- conducting silicone grease to the mating surfaces of the module and distributor. The correct grease can be obtained from Rover dealers under Part Number BAU 5812 but if this is not available, either a heat-sink compound or an anti-seize compound (such as Holt’s Copaslip), will serve as an adequate substitute. 7Check that the terminal pins are not bent or damaged and that they engage correctly with the module’s connections. 8Tighten the module retaining bolts to the specified torque wrench setting, then reconnect the distributor wiring and battery. 7 Thermostatically-operated vacuum switch- removal and refitting 2 1On models fitted with a catalytic converter, a thermostatically-operated vacuum switch is screwed into the cooling system thermostat housing. Removal 2Either drain the cooling system or be prepared for some loss of coolant as the switch is unscrewed. 3Access to the thermostat housing ispossible with the inlet manifold and carburettor in place, but is made much easier if these are first removed. 4Disconnect and plug the switch vacuum pipes. 5Unscrew the switch and withdraw it, then plug the opening to prevent the entry of dirt. If the cooling system has not been drained, work quickly to minimise coolant loss. 6If required, the switch can be tested as described in Chapter 3. Refitting 7Refitting is the reverse of the removal procedure, noting the following: a) Wipe clean the threads of the switch and thermostat housing. b) If a sealing washer is fitted, renew it whenever it is disturbed so as to prevent leaks. If no sealing washer is fitted, apply a smear of sealant to the switch threads. c) Tighten the switch securely and reconnect the vacuum pipes. d) Refit any components removed to improve access. e) Replenish the cooling system. 8 Ignition timing- checking and adjustment Refer to Chapter 1. 9 Ignition system- testing 3 Note:Always switch off the ignition before disconnecting or connecting any system component and when using a multi-meter to check resistances. Any voltmeter or multi- meter used to test ignition system components must have an impedance of 10 Mohms or greater. General 1The components of electronic ignition systems are normally very reliable. Most faults are likely to be due to loose or dirty connections or to ‘tracking’ of HT voltage due to dirt, dampness or damaged insulation, than to the failure of any of the system’s components. Always check all wiring thoroughly before condemning an electrical component and work methodically to eliminate all other possibilities before deciding that a particular component is faulty. 2The old practice of checking for a spark by holding the live end of an HT lead a short distance away from the engine is not recommended. Not only is there a high risk of a powerful electric shock but the HT coil or amplifier module will be damaged. Never try to diagnose misfires by pulling off one HT lead at a time. Engine will not start 3If the engine will not turn over at all or only turns very slowly, check the battery and starter motor. Connect a voltmeter across the battery terminals (meter positive probe to battery positive terminal), disconnect the ignition coil HT lead from the distributor cap and earth it, then note the voltage reading obtained while turning over the engine on the starter for (no more than) ten seconds. If the reading obtained is less than approximately 9.5 volts, check the battery, starter motor and charging system. 4If the engine turns over at normal speed but will not start, check the HT circuit by connecting a timing light (following the manufacturer’s instructions) and turning the engine over on the starter motor. If the light flashes then voltage is reaching the spark plugs, so these should be checked first. If the light does not flash, check the HT leads themselves followed by the distributor cap, carbon brush and rotor arm. 5If there is a spark, check the fuel system for faults. 6If there is still no spark, check the voltage at the ignition HT coil + terminal. It should be the same as the battery voltage (ie: at least 11.7 volts). If the voltage at the coil is more than 1 volt less than that at the battery, check the feed back through the fusebox and ignition switch to the battery and its earth until the fault is found. 7If the feed to the HT coil is sound, check the coil’s primary and secondary winding resistance. Renew the coil if faulty but be careful to carefully check the condition of the LT connections themselves before doing so, to ensure that the fault is not due to dirty or poorly-fastened connectors. 8If the HT coil is in good condition, the fault is probably within the amplifier module or distributor pick-up coil. So that the operation of these two can be checked quickly, Rover dealers have a neon indicator, which when connected across the HT coil’s LT terminals, flashes every time the amplifier triggers an HT pulse in the coil if the ignition is switched on and the engine is turned over on the starter. Owners can substitute a low-wattage bulb. If the bulb flickers or flashes when the engine is turned over, the amplifier and distributor are sound. 9If the amplifier and distributor are sound, and the entire LT circuit is in good condition, the fault, if it lies in the ignition system, must be in the HT circuit components. These should be checked carefully, as outlined above. 10If the indicator or bulb does not flash, the fault is in either the distributor pick-up coil or the amplifier module. Owners should note that by far the commonest cause of failure of either of these is a poor connection, either between the amplifier module and the distributor body or in the LT circuit wiring connections themselves. If a voltmeter or Ignition system - carburettor engines 5A•5 5A 1689 Rover 214 & 414 Updated Version 09/97
multi-meter is available, check the feed to the amplifier (the voltage reading obtained should be the same as that measured at the HT coil LT + terminal), then check that there is no measurable resistance between the amplifier module fixing screws and engine earth and that there is no continuity between either module terminal and earth. If any doubt exists as to the condition of the connections, remove the module, clean and check carefully the module earth and the connections and, if necessary, improve their fit. If these checks fail to correct the fault, measure the resistance of the pick-up coil, comparing it with the specified value. Renew the coil if the reading obtained differs significantly from that given. Ifthe fault still exists, the only solution is to try the effect of renewing the amplifier module. Engine misfires 11An irregular misfire suggests either a loose connection or intermittent fault on the primary circuit, or an HT fault on the coil side of the rotor arm. 12With the ignition switched off, check carefully through the system ensuring that all connections are clean and securely fastened. If the equipment is available, check the LT circuit as described in paragraphs 6 to 10 above. 13Check that the HT coil, the distributor cap and the HT leads are clean and dry. Check the leads themselves and the sparkplugs (by substitution, if necessary), then check the distributor cap, carbon brush and rotor arm. 14Regular misfiring is almost certainly due to a fault in the distributor cap, HT leads or spark plugs. Use a timing light to check whether HT voltage is present at all leads. 15If HT voltage is not present on any particular lead, the fault will be in that lead or in the distributor cap. If HT is present on all leads, the fault will be in the spark plugs. Check and renew them if there is any doubt about their condition. 16If no HT is present, check the HT coil as its secondary windings may be breaking down under load. 5A•6 Ignition system - carburettor engines 1689 Rover 214 & 414 Updated Version 09/97