Rover 214-414. Service Repair Manual

remove the heater lower mounting nut which
is situated just to the left of the matrix outlets
(see illustrations).
3 Working inside the vehicle, remove the
facia.
4 Slacken and remove the two retaining
screws and remove the blower motor-to-
heater unit duct (see illustration). On models
equipped with air conditioning, the evaporator
unit is fitted in place of the duct. It may be
possible to gain the necessary clearance
required to disengage the evaporator from the
heater unit by removing the mounting
brackets and nuts. If not, the evaporator must
be removed.
5 Undo the screw securing the right-hand
heater duct to the mounting bracket, then
move the duct to the right to disengage it from
the heater unit (see illustrations).

6 Undo the inertia switch retaining nut and
disengage the switch from the steering
column support bracket.

7 Release the wiring block connector from
the right-hand end of the steering column
support bracket and undo the fusebox

3•8 Cooling, heating and ventilation systems

10.5a Undo right-hand duct retaining

screw (arrowed) . . .

10.2c . . . and free heater valve cable from

retaining clip

10.2d Slacken and remove heater unit

lower mounting nut

10.4 Remove blower motor-to-heater unit

duct

10.2b Disconnect heater feed and return

hoses . . .

10.2a Heater unit components

Heater case

Heater case clip

Face level/windscreen
duct

Floor level duct

Heater matrix

Heater matrix cover

Cable retaining clip

8 Floor level flap operating

lever

9 Clip

10 Floor level flap idler lever
11 Face level flap idler lever
12 Flap operating lever
13 Air mix flap operating lever
14 Air mix flap

15 Ambient air flap - centre

console vents

16 Distribution flap -

windscreen

17 Distribution flap - face

level vents

18 Distribution flap - floor

level vents

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

retaining nut. Slacken and remove the five
support bracket retaining bolts and remove
the bracket from the vehicle (see
illustrations).
8 Disconnect the air recirculation cable inner
from the flap and free the cable outer from the
blower motor.
9 Prise out the stud securing the rear heater
duct sleeve to the bottom of the heater unit,
then slide the sleeve down to disengage it
from the unit (see illustration).
10 Disconnect the wiring connectors from
the heater control panel, then remove the two
upper heater unit retaining nuts and carefully
manoeuvre the heater unit out of the vehicle
(see illustrations).

Heater matrix

11 Remove the heater unit.
12 Undo the screw securing the matrix outlet
pipe bracket to the heater unit and remove the
bracket (see illustration).
13 Slacken and remove the two matrix cover
retaining screws, then remove the cover and
withdraw the matrix from the heater unit (see
illustrations).
14 If the matrix is leaking, it is best to obtain
a new or reconditioned unit as home repairs
are seldom successful. If it is blocked, it can
sometimes be cleared by reverse flushing
using a garden hose. Use a proprietary
radiator cleaning product if absolutely
necessary.

Cooling, heating and ventilation systems 3•9

10.7b Remove mounting bolts and

manoeuvre steering column mounting

bracket out of position

10.7a Release wiring connector from

steering column support bracket and

remove fusebox nut (arrowed)

10.5b . . . and disengage duct from heater

unit

10.13c . . . and withdraw matrix from

heater unit

10.13b . . . then remove cover . . .

10.12 Undo retaining screw and remove

matrix outlet pipe bracket

10.10b . . . and remove heater retaining

nuts

10.10a Disconnect wiring from heater

control panel . . .

10.9 Remove retaining stud and disengage

rear heater duct sleeve from heater unit

10.13a Undo two matrix cover retaining

screws . . .

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Heater blower motor

15 Undo the two glovebox retaining screws
then partially withdraw the glovebox until
access can be gained to the glovebox damper
to facia screw. Undo the damper screw and
remove the glovebox and damper (see
illustration).
16 Slacken and remove the four glovebox
support rail mounting bolts and remove the
rail (see illustration).
17 Slacken and remove the two retaining
screws and remove the blower motor-to-
heater unit duct (see illustration). On models
equipped with air conditioning, the evaporator
unit is fitted in place of the duct. It may be
possible to gain the necessary clearance

required to disengage the evaporator and
remove the blower motor by removing the
mounting brackets and nuts. If not, the
evaporator must be removed.
18 Disconnect the air recirculation cable
inner from the flap and free the cable outer
from the blower motor. Disconnect the two
blower motor wiring connectors (see
illustration).
19 Slacken and remove the three blower
motor mounting bolts and manoeuvre the
blower unit out from underneath the facia (see
illustrations).
20 To remove the motor from the unit, undo
the four motor cover retaining screws, then
disconnect the breather hose and lift off the

cover. Slacken and remove the three motor
retaining bolts and withdraw the motor
assembly from the blower unit. Undo the fan
retaining nut and separate the fan and motor,
noting the seal fitted between the two
components (see illustrations).

Heater blower motor resistor

21 Remove the glovebox as described in
paragraphs 15 and 16.
22 Disconnect the wiring connector, then
undo the two retaining screws and remove the
resistor from the front of the motor assembly.

Heater valve

23 Working in the engine compartment,
disconnect the cable inner from the heater

3•10 Cooling, heating and ventilation systems

10.20c Undo motor retaining bolts and

withdraw motor from unit

10.20b . . . and disconnect breather hose

10.20a Remove motor cover retaining

screws (arrowed) . . .

10.19b . . . and remove unit from behind

facia

10.19a Undo three blower motor mounting

bolts (arrowed) . . .

10.18 Disconnect motor wiring connec-

tors (A) and air recirculation cable (B)

10.17 . . . then remove blower motor-to-

heater unit duct

10.16 Remove glovebox support rail . . .

10.15 Glovebox damper retaining screw

(arrowed)

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

valve and free the cable outer from the
retaining clip.
24 Slacken and remove the bolt securing the
heater valve mounting bracket to the engine
compartment bulkhead.
25 Either drain the cooling system or clamp
the coolant hoses on each side of the coolant
valve to minimise the loss of coolant.
26 Slacken the hose retaining clips, then
disconnect both hoses from the coolant valve
and remove the valve from the engine
compartment. Mop up any spilt coolant
immediately.

Refitting

Heater unit

27 Refitting is a reverse of the removal
procedure, noting the following:
a)

Ensure that the heater ducts are securely
connected to the unit so that there are no
air leaks or gaps.

Check the operation of all heater cables
before refitting the facia, ensuring that the
relevant component moves smoothly from
the fully open to the fully closed position.
If necessary, adjustments can be made by
releasing the relevant retaining clip and
repositioning the cable outer.

Ensure that the heater hoses are correctly
reconnected and are securely held by the
retaining clips.

Tighten the heater lower mounting nut to
the specified torque setting.

Refill the cooling system as described in
Chapter 1.

Heater matrix

28 Refitting is a reverse of the removal
procedure.

Heater blower motor

29 Refitting is a reversal of the removal
sequence, noting the following:
a)

Ensure that the foam rubber seal is
refitted correctly so that the blower
motor-to-bulkhead aperture is closed off.

Tighten the blower motor mounting bolts
to the specified torque setting.

Ensure that the air recirculation cable and
flap functions correctly before refitting the
glovebox. If necessary, adjust by releasing
the cable retaining clip and repositioning
the cable outer.

Heater blower motor resistor

30 Refitting is a reverse of the removal
procedure.

Heater valve

31 Refitting is a reversal of the removal
procedure. On completion, check the heater
cable operates smoothly and replenish the
cooling system.

11 Heater ducts and vents -

removal and refitting

Removal

Facia ducts

1 Remove the facia.

2 The ducts are mounted on the facia
assembly and can be removed individually,
once the retaining screws have been
removed.

Heater unit ducts

3 The left-hand heater unit to blower
motor duct is removed as described in
paragraphs 15 to 17 of Section 10.
4 To remove the right-hand duct, first remove
the facia. Slacken and remove the retaining
screw which secures the right-hand end of the
duct to the mounting bracket and release the
radio aerial from the retaining clips on the
underside of the duct. The duct can then be
manoeuvred out of position.
5 Removal of the lower ducts which supply
air to the rear passenger footwells is a
complex job, requiring the removal of the front
seats, centre console and the various trim
panels so that the floor carpet can be peeled
back, and is therefore not recommended.

Centre console vents

6 Remove the centre console.
7 The vents can then be unclipped from the
rear of the front console section and removed.

Facia vents

8 The adjustable face-level vents can be
removed by prising them gently out of the
facia until the clips are released, taking care
not to mark the facia.
9 The door window demister vents, fitted to
the sides of the facia, can also be prised out
of position once the relevant door has been
opened.

Refitting

10 Refitting is a reverse of the removal
procedure.

12 Heater controls - removal,

refitting and adjustment

Removal

1 Remove the heater unit.
2 Disconnect the heater control cables from
the heater unit and unclip the control panel.
Remove the panel assembly complete with
cables (see illustrations).

Refitting and adjustment

3 Refit the heater control panel to the heater
unit and reconnect the necessary control
cables to their original positions.
4 Check the operation of the control cables,
ensuring that they operate smoothly and
move the necessary component from the fully
open to the fully closed position. Adjustments
can be made by releasing the cable retaining
clip and repositioning the cable outer.
5 Once the necessary control cables are
functioning correctly, refit the heater unit.

Cooling, heating and ventilation systems 3•11

10.20e . . . and lift off fan (seal arrowed)

10.20d Remove fan retaining nut . . .

12.2b . . . and remove heater control panel

with cables

12.2a Disconnect control cables from

heater unit . . .

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

13 Air conditioning compressor

drivebelt - inspection,
adjustment and renewal

Refer to Chapter 1 (alternator drivebelt check).

14 Air conditioning refrigerant -

level check

Refer to Chapter 1.

15 Air conditioning system

components -
removal and refitting

Warning: The air conditioning
system must be professionally
discharged before carrying out
any of the following work. Cap

or plug the pipe lines as soon as they are
disconnected to prevent the entry of
moisture.

Compressor

Removal

1 Remove the alternator/air conditioning
compressor drivebelt as described in Chap-
ter 1.
2 Disconnect the air conditioning pipes from
the compressor (see illustration).
3 Slacken and remove the four bolts securing
the compressor to the mounting bracket and
manoeuvre it downwards and away from the
engine.

Refitting

4 Refitting is a reverse of the removal
sequence, tightening the compressor
mounting bolts to the specified torque setting.
Ensure that the compressor pipe unions are
securely tightened then refit and adjust the
drivebelt as described in Chapter 1. On
completion, have the air conditioning system
recharged by a refrigeration specialist or
suitably-equipped Rover dealer.

Condenser

Removal

5 Remove the front bumper.
6 Slacken and remove the bolts securing the
power steering oil cooler to the body, then
undo the bonnet lock mounting bracket bolts
and position the lock assembly clear of the
condenser unit.
7 Unscrew the air conditioning pipe union
nuts from the condenser unit then disconnect
the pipes. Discard the union pipe O-rings as
these must be renewed whenever they are
disturbed.
8 Slacken and remove the four retaining bolts
and withdraw both the condenser upper
mounting brackets. Release the condenser
from its lower mounting points and
manoeuvre it away from the vehicle.

Refitting

9 Prior to refitting, check the condenser lower
mounting rubbers for signs of damage or
deterioration and renew as necessary. Renew
the pipe union O-rings.
10 Refitting is a direct reversal of the removal
procedure, tightening the pipe union nuts to
the specified torque setting. On completion,
have the air conditioning system recharged by
a refrigeration specialist or a suitably
equipped Rover dealer.

Condenser cooling fan

Removal

11 Drain the cooling system.
12 Disconnect the wiring connector from the
engine overheat switch, located in the top
coolant hose, then slacken the clips securing
the hose to the radiator and engine.
Disconnect the hose from the radiator and
engine and position it clear of the condenser
so that it does not hinder removal.
13 Disconnect the condenser fan electrical
wiring connector then undo the four fan
cowling retaining nuts and manoeuvre the
assembly out of the engine compartment.

14 To dismantle the assembly, first undo the
fan retaining nut then lift the fan off the motor
spindle. Undo the two screws which secure
the motor assembly to the cowling then
release the motor wiring and connector and
separate the motor and cowling.

Refitting

15 Refitting is a reverse of the removal
procedure, noting the following points:
a)

Ensure that the motor wiring is securely
retained by the cowling clips and is clear
of the condenser fan.

Ensure that the radiator hose is securely
held by its retaining clips.

On completion, refill the cooling system.

Evaporator

Removal

16 Undo the three bolts which secure the
washer system reservoir to the engine
compartment bulkhead and move the
reservoir to gain access to the two evaporator
union nuts. Slacken both the union nuts and
disconnect the pipes from the evaporator.
Remove the O-rings from the union nuts and
discard them.

3•12 Cooling, heating and ventilation systems

15.2 Air conditioning system layout

1 Compressor
2 Condenser
3 Receiver drier
4 Evaporator

5 Heater unit
6 Blower unit
7 High pressure servicing

connection

8 Low pressure servicing

connection

9 Trinary switch

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

17 Working from inside the vehicle, undo the
two glovebox retaining screws, then partially
withdraw the glovebox until access can be
gained to the glovebox damper-to-facia
screw. Undo the damper screw and remove
the glovebox and damper.
18 Slacken and remove the four glovebox
support rail mounting bolts and remove the
rail.
19 Undo the two evaporator bracket
retaining bolts and remove both the brackets.
20 Disconnect the wiring connector from the
right-hand side of the evaporator.
21 Slacken and remove the two evaporator
mounting nuts and manoeuvre the unit out of
position.

Refitting

22 Refitting is a reverse of the removal
procedure noting the following:
a)

Ensure that the evaporator is correctly
joined to the heater unit and blower
motor, so that there are no air leaks or
gaps, then tighten the retaining nuts and
bracket bolts securely.

Fit new O-rings to the pipe unions and

tighten the union nuts to the specified
torque setting.

On completion, have the system
recharged by a refrigeration specialist or a
suitably-equipped Rover dealer.

Receiver drier

Removal

23 Remove the left-hand headlamp and the
battery and battery tray.
24 Undo the two screws securing the air
intake grille to the body. Disengage the grille
from the resonator and remove it from the
vehicle. Move the resonator to one side to
gain access to the receiver drier.
25 Slacken the union nuts and disconnect
the pipes from the receiver drier noting the O-
rings which are fitted to the pipe unions.
Discard the O-rings as they must be renewed
whenever they are disturbed. The receiver
drier unit unions must be capped immediately
after they are disconnected and must remain
capped until they are to be reconnected. If the
receiver drier unit is left uncapped for any
period of time it must be renewed.

26 Slacken the receiver drier clamp bolt then
slide the unit out of the retaining clamp and
remove it from the engine compartment.

Refitting

27 Refitting is a direct reversal of the removal
sequence, tightening the pipe union nuts to
the specified torque setting. On completion,
have the system recharged by a refrigeration
specialist or suitably-equipped Rover dealer.

Trinary switch

Removal

28 Remove the front bumper.
29 Disconnect the wiring connector and
unscrew the switch from the air conditioning
pipe. Remove the O-ring from the switch and
discard it.

Refitting

30 Refitting is a reverse of the removal
procedure. Fit a new O-ring to the switch and
tighten it to the specified torque setting. On
completion, have the system recharged by a
refrigeration specialist or suitably-equipped
Rover dealer.

Cooling, heating and ventilation systems 3•13

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1689 Rover 214 & 414 Updated Version 09/97

Chapter 3
Cooling, heating and ventilation systems

Air conditioning compressor drivebelt - inspection, adjustment

and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Air conditioning refrigerant - level check . . . . . . . . . . . . . . . . . . . . . . 14
Air conditioning system components - removal and refitting . . . . . . 15
Coolant pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system - draining, flushing and filling . . . . . . . . . . . . . . . . .

Cooling system - general inspection . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system electrical switches - testing, removal and refitting .

Cooling system hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric cooling fan - testing, removal and refitting . . . . . . . . . . . . . .

General information and precautions . . . . . . . . . . . . . . . . . . . . . . . .

Heater components - removal and refitting  . . . . . . . . . . . . . . . . . . . 10
Heater controls - removal, refitting and adjustment  . . . . . . . . . . . . . 12
Heater ducts and vents - removal and refitting . . . . . . . . . . . . . . . . . 11
Radiator and expansion tank - removal, inspection and refitting  . . .

Thermostat - removal, testing and refitting . . . . . . . . . . . . . . . . . . . .

3•1

Contents

Specifications

System

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressurised, pump-assisted thermo-syphon with front mounted
radiator and thermostatically-controlled electric cooling fan

Thermostat

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wax

Start to open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 to 80°C

Fully open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 or 88°C (actual value stamped in unit end)

Full lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.0 mm

Expansion tank

Cap pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.9 to 1.0 bar

Cooling fan

Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 to 92°C

Torque wrench settings

lbf ft

Cooling system

Fan motor nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature gauge sender unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat housing cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat housing/dipstick tube-to-cylinder block/crankcase bolt . . .

Coolant rail-to-cylinder block/crankcase bolts . . . . . . . . . . . . . . . . . . . .

Coolant pump-to-timing belt upper left-hand (inner) cover bolt . . . . . .

Coolant pump-to-cylinder block/crankcase bolts . . . . . . . . . . . . . . . . .

Heating system

Heater lower mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater blower motor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning system

Compressor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condenser unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporator inlet union (from receiver drier) . . . . . . . . . . . . . . . . . . . . . .

Evaporator outlet union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiver drier union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trinary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

-------------------------------------------------------------------------------------------------------------------------------------------------------------

General information and
precautions

General information

The cooling system is of the pressurised,

pump-assisted thermo-syphon type. It
consists of the front-mounted radiator, a
translucent expansion tank mounted on the
right-hand inner wing, a thermostatically-
controlled electric cooling fan mounted on the
rear of the radiator, a thermostat and a
centrifugal coolant pump, as well as the
connecting hoses (see illustration). The
coolant pump is driven by the engine timing
belt.

The system is of the by-pass type, allowing

coolant to circulate around the engine while
the thermostat is closed. With the engine
cold, the thermostat closes off the coolant
feed from the bottom radiator hose. Coolant is
then drawn into the engine via the heater
matrix, inlet manifold and from the top of the
cylinder block. This allows some heat transfer,
by convection, to the radiator through the top

hose whilst retaining the majority of heat
within the cylinder block.

The siting of the thermostat in the intake

rather than the outlet side of the system
ensures that the engine warms up quickly by
circulating a small amount of coolant around a
shorter tract. This also prevents temperature
build-up in the cylinder head prior to the
thermostat opening.

When the coolant reaches a predetermined

temperature, the thermostat opens and the
coolant is allowed to flow freely through the
top hose to the radiator. As the coolant
circulates through the radiator, it is cooled by
the inrush of air when the vehicle is in forward
motion. Airflow is supplemented by the action
of the electric cooling fan when necessary.
Upon reaching the bottom of the radiator, the
coolant is now cooled and the cycle is
repeated.

With the engine at normal operating

temperature, the coolant expands and some
of it is displaced into the expansion tank. This
coolant collects in the tank and is returned to
the radiator when the system cools.

The electric cooling fan mounted behind

the radiator is controlled by a thermostatic

switch located in the radiator side tank.
At a predetermined coolant temperature
the switch contacts close, thus actuating the
fan.

Precautions

Cooling system

Do not attempt to remove the expansion

tank filler cap or to disturb any part of the
cooling system whilst it or the engine is hot,
as there is a very great risk of scalding. If the
expansion tank filler cap must be removed
before the engine and radiator have fully
cooled down (even though this is not
recommended) the pressure in the cooling
system must first be released. Cover the cap
with a thick layer of cloth, to avoid scalding,
and slowly unscrew the filler cap until a
hissing sound can be heard. When the hissing
has stopped, showing that pressure is
released, slowly unscrew the filler cap until
it can be removed. If more hissing sounds
are heard, wait until they have stopped
before unscrewing the cap completely. At
all times keep well away from the filler
opening.

Do not allow antifreeze to come in contact

with your skin or painted surfaces of the
vehicle. Rinse off spills immediately with
plenty of water. Never leave antifreeze lying
around, it is fatal if ingested.

If the engine is hot, the electric cooling fan

may start rotating even if the engine is not
running, so be careful to keep hands, hair and
loose clothing well clear when working in the
engine compartment.

Air conditioning system

On models equipped with an air

conditioning system, it is necessary to
observe special precautions whenever dealing
with any part of the system, its associated
components and any items which necessitate
disconnection of the system. If for any reason
the system must be disconnected, entrust this
task to your Rover dealer or a refrigeration
engineer.

Refrigerant must not be allowed to come in

contact with a naked flame, otherwise a
poisonous gas will be created. Do not allow
the fluid to come in contact with the skin or
eyes.

Cooling system - draining,
flushing and refilling

Refer to Chapter 1.

Cooling system -
general inspection

Refer to “Weekly Checks” and Chapter 1.

3•2 Cooling, heating and ventilation systems

1.0 Cooling system components

1 Radiator
2 Cooling fan and cowling
3 Radiator mounting

rubbers

4 Bottom hose
5 Top hose
6 Coolant pipe - bottom

hose to thermostat
housing

7 Thermostat housing

cover

8 Gasket

9 Thermostat

10 Thermostat housing
11 O-ring
12 Coolant pump
13 Expansion tank
14 Hose - heater matrix and

manifold return

15 Hose - heater matrix and

manifold feed

16 Heater temperature

control valve

17 Coolant filler stem

18 Cooling system bleed

screw

19 Engine overheat switch -

where fitted

20 Coolant pipe - expansion

tank to bottom hose

21 Hose - expansion tank

return

22 Sealing ring
23 Cooling fan thermostatic

switch

24 Locking ring

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Cooling system hoses -
renewal

1 If inspection of the cooling system reveals a
faulty hose, then it must be renewed as
follows.
2 First drain the cooling system. If the coolant
is not due for renewal, it may be re-used if
collected in a clean container.
3 To disconnect any hose, use a screwdriver
to slacken the clips then move them along the
hose clear of the outlet. Carefully work the
hose off its outlets. Do not attempt to
disconnect any part of the system when still
hot.
4 Note that the radiator hose outlets are
fragile. Do not use excessive force when
attempting to remove the hoses. If a hose
proves stubborn, try to release it by rotating it
on its outlets before attempting to work it off.
If all else fails, cut the hose with a sharp knife
then slit it so that it can be peeled off in two
pieces. While expensive, this is preferable to
buying a new radiator.
5 When refitting a hose, first slide the clips
onto the hose then work the hose onto its
outlets. If the hose is stiff, use soap as a
lubricant or soften it by first soaking it in
boiling water whilst taking care to prevent
scalding.
6 Work each hose end fully onto its outlet,
check that the hose is settled correctly and is
properly routed, then slide each clip along the
hose until it is behind the outlet flared end
before tightening it securely.
7 Refill the system with coolant.
8 Check carefully for leaks as soon as
possible after disturbing any part of the
cooling system.

Radiator and expansion tank
- removal, inspection and
refitting

Removal

Radiator

1 Drain the cooling system.
2 On models equipped with air conditioning,
remove the condenser fan, then undo the two
bolts securing the air conditioning pipes to the
bonnet platform.
3 Remove the air cleaner metal intake duct
and intake hose.
4 Disconnect the radiator cooling fan wiring
connector, then slacken and remove the bolt

securing the earth leads to the bonnet platform.
Disconnect the wiring from the thermostatic
switch(es) which are fitted to the right-hand
side of the radiator (see illustrations).
5 Slacken the bottom hose retaining clip and
disconnect the hose from the radiator.
6 Slacken the retaining clips and disconnect
the top hose from both the radiator and
engine coolant elbow (see illustrations).
Position the hose clear of the radiator so that
it does not hinder removal.
7 Undo the two bolts securing the upper
mounting brackets to the bonnet platform and
remove the brackets from the radiator.
Disengage the radiator from its lower mounting
points and carefully manoeuvre it out of the
engine compartment (see illustrations).

Cooling, heating and ventilation systems 3•3

5.6a Slacken clips and disconnect top

hose from radiator . . .

5.4b Disconnecting wiring connector from

radiator switch

5.7a Undo radiator mounting bolts . . .

5.6b . . . and engine coolant elbow

5.7c . . . and manoeuvre radiator out of

engine compartment

5.7b . . . remove mounting brackets . . .

5.4a Disconnect cooling fan wiring

connector then remove earth lead

retaining bolt (arrowed)

1689 Rover 214 & 414 Updated Version 09/97

Never work on the cooling
system when it is hot.
Release any pressure from
the system by loosening the

expansion tank cap, having first
covered it with a cloth to avoid any
possibility of scalding.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Expansion tank

8 Slacken and remove the three bolts
securing the expansion tank to the body.
Unscrew the expansion tank cap and tip out
its contents into a suitable container.
9 Slacken the retaining clips then disconnect
both the hoses from the expansion tank and
remove the tank from the vehicle.

Inspection

Radiator

10 If the radiator was removed because of
clogging (causing overheating) then try
reverse flushing or, in severe cases, use a
radiator cleanser strictly in accordance with
the manufacturer’s instructions. Ensure
that the cleanser is suitable for use in a
copper/brass radiator. Refer to Chapter 1 for
further information
11 Use a soft brush and an air line or garden
hose to clear the radiator matrix of leaves,
insects etc.

12 Major leaks or extensive damage should
be repaired by a specialist, or the radiator
should be renewed or exchanged for a
reconditioned unit.
13 Examine the mounting rubbers for signs
of damage or deterioration and renew if
necessary.

Expansion tank

14 Empty any remaining coolant from the
tank and flush it with fresh water to clean it. If
the tank is leaking it must be renewed but it is
worth first attempting a repair using a
proprietary sealant or suitable adhesive.
15 The expansion tank cap should be
cleaned and checked whenever it is removed.
Check that its sealing surfaces and threads
are clean and undamaged and that they mate
correctly with those of the expansion tank.
16 The cap’s performance can only be
checked by using a cap pressure-tester
(cooling system tester) with a suitable

adaptor. On applying pressure, the cap’s
pressure relief valve should hold until the
specified pressure is reached, at which point
the valve should open.
17 If there is any doubt about the cap’s
performance, then it must be renewed. Ensure
that the replacement is of the correct type and
rating.

Refitting

Radiator

18 Refitting is the reverse of the removal
procedure whilst noting the following:
a)

Ensure that the radiator is seated
correctly and without strain on its
mountings.

Ensure that the radiator hoses are
securely held by the retaining clips.

Ensure that all wiring connectors are
correctly routed so that they are clear of
the cooling fan and are retained by any
necessary clips or ties.

Refill the cooling system as described in
Chapter 1.

Expansion tank

19 Refitting is the reverse of the removal
procedure whilst noting the following:
a)

Ensure that all hoses are correctly routed
with no kinks or sharp bends and are
securely held by the retaining clips.

Top up the expansion tank as described
in Chapter 1.

Thermostat -
removal, testing and refitting

Removal

1 Note that access to the thermostat is very
limited. Depending on the tools available, it
may be easier to raise the front of the vehicle
and to work from underneath, ensuring that
the vehicle is securely supported on axle
stands. In most cases, access is better if the
air cleaner and carburettor (or throttle body on
SPi engines) are removed and is best if the
complete inlet manifold is removed. If the inlet
manifold is removed, the thermostat housing

cover can be unbolted to remove the
thermostat without disturbing the housing
itself (see illustration). Whichever method is
used, first drain the cooling system.
2 On carburettor models equipped with a
catalytic converter, either remove the
thermostatically-operated vacuum switch or
disconnect the vacuum pipes from the switch
so that it can be removed with the thermostat
housing.
3 Unbolt the coolant rail from the rear of the
cylinder block/crankcase, then slacken the
clips and disconnect the coolant rail hose and
heater/inlet manifold return hose from the
thermostat housing (see illustration).
4 Undo the thermostat housing/dipstick tube-
to-cylinder block/crankcase bolt and remove
the thermostat housing from the cylinder
block/crankcase. Remove the housing O-ring
which must be renewed whenever it is
disturbed (see illustrations).
5 Slacken and remove the three thermostat
housing cover bolts and lift off the housing
cover. Discard the gasket and remove the
thermostat.

Testing

6 If the thermostat remains in the open
position at room temperature, then it is faulty
and must be renewed.
7 To test it fully, suspend the (closed)
thermostat on a length of string in a container
of cold water, with a thermometer beside it.

3•4 Cooling, heating and ventilation systems

6.4b . . . and withdraw thermostat housing

(O-ring arrowed) – inlet manifold removed

for clarity

6.4a . . . unscrew dipstick tube retaining

bolt . . .

6.3 Disconnect coolant rail and

heater/inlet manifold hoses (arrowed) . . .

6.1 Thermostat can be removed without

disturbing housing if inlet manifold is first

removed

1689 Rover 214 & 414 Updated Version 09/97

Minor leaks from the
radiator can be cured using
a suitable sealant with the
radiator in situ.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Ensure that neither touches the side of the
container (see illustration).
8 Heat the water and check the temperature
at which the thermostat begins to open.
Compare this value with that specified.
Continue to heat the water until the
thermostat is fully open. The temperature at
which this should happen is stamped in the
unit’s end (see illustration). Remove the
thermostat and measure the height of the fully
opened valve, then allow the thermostat to
cool down and check that it closes fully.
9 If the thermostat does not open and close
as described, if it sticks in either position, or if
it does not open at the specified temperature,
then it must be renewed.

Refitting

10 Refitting is the reverse of the removal
procedure, noting the following (see
illustration):
a)

Clean the thermostat housing, housing
cover and cylinder block/crankcase
mating surfaces thoroughly.

Always fit a new housing cover gasket
and O-ring. Smear the O-ring with grease
to aid refitting.

Tighten all bolts to their specified torque
wrench settings (where given).

Ensure the coolant hose clips are
positioned so that they do not foul any
other component, then tighten them
securely.

Refit any components removed for
improved access.

Refill the cooling system as described in
Chapter 1.

Coolant pump -
removal and refitting

Removal

1 Coolant pump failure is usually indicated by
coolant leaking from the gland behind the
pump bearing, or by rough and noisy
operation, usually accompanied by excessive
pump spindle play. If the pump shows any of
these symptoms then it must be renewed as
follows.
2 Drain the cooling system.
3 Remove the timing belt.
4 Noting the location of the pillar bolt(s),
unscrew the five bolts securing the coolant
pump to the cylinder block/crankcase, then
unscrew the single bolt securing the pump to
the timing belt upper left-hand (inner) cover.
5 Withdraw the coolant pump and discard its
sealing ring which should be renewed
whenever it is disturbed. Carefully clean the
cylinder block/crankcase mating surface and
the pump socket (see illustration).

Refitting

6 On refitting, install the pump using a new
sealing ring and tighten all bolts to the
specified torque wrench settings.
7 The remainder of the refitting procedure is
the reverse of removal.

Electric cooling fan -
testing, removal and refitting

Note:

On models equipped with air

conditioning, there are two switches fitted to
the right-hand side of the radiator, the lower of
these is the cooling fan switch.

Testing

1 The cooling fan motor is supplied with
current via the ignition switch, fuse 4 and the
cooling fan relay. The relay is energised by the
radiator-mounted thermostatic switch which
is fed via fuse number 15.

2 If the fan does not appear to work, first
check that both fuses are in good condition
and have not blown. Run the engine until
normal operating temperature is reached,
then allow it to idle. If the fan does not cut in
within a few minutes, switch off the ignition
and disconnect the two wires from the
thermostatic switch. Bridge these two wires
with a length of spare wire and switch on the
ignition. If the fan now operates, the
thermostatic switch is probably faulty and
must be tested further as described in
Section 9.
3 If the fan still fails to operate, check that full
battery voltage is available at the switch’s
light green and grey wire terminal. If not,
check the feed for a blown fuse or other fault
such as a broken wire. If the feed is good,
check the cooling fan relay, see Chapter 12. If
the relay operates correctly, check for
continuity between the fan motor black wire
terminal and a good earth point on the body. If
not, then the earth connection is faulty and
must be remade. The circuit earth connection
is one of those at earth header 1, attached to
the left-hand inner wing panel next to the
battery.
4 If the switch and wiring are in good
condition, the fault must be in the motor itself.
This can be checked by disconnecting it from
the wiring loom and connecting a 12 volt
supply directly to it. If the motor does not
work then it must be renewed.

Removal

5 Drain the cooling system, then jack up the
front of the vehicle and support it securely on
axle stands.
6 From underneath the front of the vehicle,
slacken and remove the three bolts securing
the bumper flange to the body. Remove the
seven bolts securing the front undercover
panel to the body and remove the panel.
7 Remove the air cleaner metal intake duct
and intake hose.
8 Slacken the retaining clips and disconnect
the top hose from both the radiator and
engine. Position the hose clear of the radiator
so that it does not hinder removal.
9 Disconnect the radiator cooling fan wiring
connector.

Cooling, heating and ventilation systems 3•5

6.10 Thermostat housing and coolant

hoses refitted

6.8 Note temperature specification

stamped on thermostat end

6.7 Testing the thermostat

7.5 Removing the coolant pump

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

10 Undo the four nuts securing the cooling
fan cowling to the rear of the radiator and
manoeuvre the fan assembly out of the engine
compartment (see illustrations).
11 To dismantle the assembly, first prise off
the fan retaining circlip, then lift the fan off the
motor spindle. Undo the three nuts which
secure the motor assembly to the cowling
then release the motor wiring and connector
and separate the motor and cowling (see
illustration).

Refitting

12 Refitting is a reverse of the removal
procedure, noting the following:
a)

If necessary, reassemble the fan motor,
cowling and fan, then tighten the motor
retaining nuts to the specified torque.
Ensure that the motor wiring is securely
retained by the cowling clips.

Ensure that the radiator hose is securely
held by its retaining clips.

On completion, refill the cooling system
as described in Chapter 1.

Cooling system electrical
switches - testing, removal
and refitting

Note:

On models equipped with air

conditioning, there are two switches fitted to
the right-hand side of the radiator, the lower of
these is the cooling fan switch.

Testing

Cooling fan thermostatic switch

1 Refer to Section 8 for details of a quick test
which should eliminate most faulty switches.
If the switch is to be renewed, or to be tested
thoroughly, it must be removed.
2 To carry out a thorough test of the switch,
use two spare wires to connect to it either a
multimeter (set to the resistance function) or a
battery and bulb test circuit. Suspend the
switch in a pan of water which is being
heated. Measure the temperature of the water
with a thermometer. Do not let either the
switch or the thermometer touch the pan itself
(see illustration).

3 The switch contacts should close to the ON
position (ie: continuity should exist) when the
water reaches the temperature specified.
Stop heating the water and allow it to cool
down. The switch contacts should open.
4 If the switch’s performance is significantly
different from that specified, or if it does not
work at all, then it must be renewed.

Coolant temperature gauge sender
unit

5 The coolant temperature gauge mounted in
the instrument panel is fed with a stabilised 10
volt supply from the instrument panel feed (via
the ignition switch and fuse 1), its earth being
controlled by the sender unit.
6 The sender unit is screwed into the coolant
outlet elbow mounted on the left-hand end of
the cylinder head, underneath the distributor
(see illustration). It contains a thermistor,
which is an element whose electrical
resistance decreases at a predetermined rate
as its temperature rises. Thus, when the
coolant is cold, the sender’s resistance is
high, current flow through the gauge is
reduced and the gauge needle points to the
C (cold) end of the scale. If the unit is faulty it
must be renewed.

7 If the gauge develops a fault, check first the
other instruments. If they do not work at all,
check the instrument panel feed. If the
readings are erratic, there may be a fault in the
voltage stabiliser which will necessitate the
renewal of the gauge unit or printed circuit. If
the fault is in the temperature gauge alone,
check it as follows.
8 If the gauge needle remains at the C end of
the scale, disconnect the sender unit wire and
earth it to the cylinder head. If the needle then
deflects when the ignition is switched on, then
the sender unit is proven faulty and must be
renewed. If the needle still does not move,
remove the instrument panel and check the
continuity of the green/blue wire between the
gauge and the sender unit and the feed to
the gauge unit. If continuity is shown and the
fault still exists, then the gauge is faulty and
the gauge unit must be renewed.
9 If the gauge needle remains at the H end of
the scale, disconnect the sender unit wire. If
the needle then returns to the C end of the
scale when the ignition is switched on, then
the sender unit is proven faulty and must be
renewed. If the needle still does not move,
check the remainder of the circuit as
described above.

Inlet manifold pre-heater temperature
switch - carburettor engines

10 The switch screwed into the underside of
the inlet manifold on carburettor engines

3•6 Cooling, heating and ventilation systems

9.6 Coolant temperature gauge sender

unit

9.2 Testing cooling system electrical

switch

8.11 Cooling fan motor retaining nuts

(arrowed)

8.10b . . . and remove fan assembly

8.10a Undo cooling fan cowling retaining

nuts (2 arrowed) . . .

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

controls the inlet manifold heater circuit (see
illustration).
11 The switch contacts should be closed to
the ON position (ie: continuity should exist)
only at temperatures below 50°C. Remove the
switch and test it as described in para-
graphs 2 to 4.

Thermostatically-operated vacuum
switch - carburettor engines equipped
with catalytic converters

12 This switch is screwed into the thermostat
housing.
13 To test the switch, fit two suitable lengths
of hose to the switch and suspend the switch
in a pan of water which is being heated.
Measure the temperature of the water
with a thermometer. Do not let either the
switch or the thermometer touch the pan
itself.
14 Blow down one of the hoses attached to
the switch. The switch should be closed (ie:
passes no air) when the water temperature is
below 70°C. Above 70°C, the switch should
open and air should flow freely through the
hoses. Stop heating the water then allow the
water to cool down and check that the switch
closes at 70°C or just below.
15 If the switch performance is significantly
different from that specified, or if it does not
work at all, then it must be renewed.

Coolant temperature sensor - fuel
injected engines

16 This sensor, which is screwed into the
underside of the inlet manifold (SPi engines),
or located in the coolant pipe adjacent to the
foward top edge of the timing belt cover (MPi
engines), is a thermistor (see paragraph 6)
which is supplied with approximately 5 volts
by the engine management system ECU. The
ECU also controls the sensor’s earth path
and, by measuring the amount of current in
the sensor circuit, determines the engine’s
temperature. This information is used, in
conjunction with other inputs, to control idle
speed, injector opening time duration and
ignition timing.
17 If the sensor circuit should fail to provide
adequate information, the ECU’s back-up

facility assumes a value corresponding to
60°C. The sensor itself can be tested only by
having a Rover dealer check the complete
system using the correct diagnostic
equipment. Do not attempt to test the circuit
using any other equipment, or the ECU will be
damaged.

Removal

Cooling fan thermostatic switch

18 With the engine and radiator cold, either
drain the cooling system down to the level of
the sender unit, or unscrew the expansion
tank filler cap to release any remaining
pressure and have a suitable plug ready that
can be used to stop the escape of coolant
while the switch is removed.
19 Disconnect the battery negative lead.
20 Disconnect the wiring connector from the
switch then rotate the locking ring to release
it. Withdraw the switch and sealing ring from
the radiator (see illustration).

Coolant temperature gauge sender
unit

21 With the engine and radiator cold, either
drain the cooling system down to the level of
the switch, or unscrew the expansion tank
filler cap to release any remaining pressure
and have a suitable plug ready that can be
used to stop the escape of coolant while the
unit is removed.
22 Disconnect the battery negative lead.
23 Disconnect the unit’s wiring connector
and unscrew the unit from the coolant outlet
elbow.

Inlet manifold pre-heater temperature
switch - carburettor engines

24 Refer to Chapter 4.

Thermostatically-operated vacuum
switch - carburettor engines equipped
with catalytic converters

25 Refer to Chapter 5.

Coolant temperature sensor - fuel
injected engines

26 Refer to Chapter 4.

Refitting

Cooling fan thermostatic switch

27 On refitting, renew the sealing ring if it is
worn or compressed and carefully clean the
radiator seat before pressing in the
sealing ring and switch (see illustration).
Refit the locking ring and rotate it to
tighten it securely. Reconnect the switch
and battery, then replenish the cooling
system.

Coolant temperature gauge sender
unit

28 On refitting, apply a suitable sealant to the
unit threads and tighten it to its specified
torque wrench setting. Reconnect the unit
and battery, then replenish the cooling
system.

Inlet manifold pre-heater temperature
switch - carburettor engines

29 Refer to Chapter 4.

Thermostatically-operated vacuum
switch - carburettor engines equipped
with catalytic converters

30 Refer to Chapter 5.

Coolant temperature sensor - fuel
injected engines

31 Refer to Chapter 4.

10 Heater components -

removal and refitting

Removal

Heater unit

1 Drain the cooling system.
2 Working in the engine compartment,
slacken the hose clips and disconnect the
heater feed and return hoses from the matrix
outlets on the bulkhead. Disconnect the cable
inner from the heater valve and free the cable
outer from its retaining clip. Slacken and

Cooling, heating and ventilation systems 3•7

9.27 Cooling fan switch locking ring (A)

thermostatic switch (B) and sealing

ring (C)

9.20 Remove cooling fan thermostatic

switch and withdraw sealing ring

(arrowed)

9.10 Inlet manifold pre-heater temperature

switch (carburettor engines)

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

6 Undo the inertia switch retaining nut and
disengage the switch from the steering
column support bracket.

7 Release the wiring block connector from
the right-hand end of the steering column
support bracket and undo the fusebox

3•8 Cooling, heating and ventilation systems

10.5a Undo right-hand duct retaining

screw (arrowed) . . .

10.2c . . . and free heater valve cable from

retaining clip

10.2d Slacken and remove heater unit

lower mounting nut

10.4 Remove blower motor-to-heater unit

duct

10.2b Disconnect heater feed and return

hoses . . .

10.2a Heater unit components

Heater case

Heater case clip

Face level/windscreen
duct

Floor level duct

Heater matrix

Heater matrix cover

Cable retaining clip

8 Floor level flap operating

lever

9 Clip

10 Floor level flap idler lever
11 Face level flap idler lever
12 Flap operating lever
13 Air mix flap operating lever
14 Air mix flap

15 Ambient air flap - centre

console vents

16 Distribution flap -

windscreen

17 Distribution flap - face

level vents

18 Distribution flap - floor

level vents

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Heater matrix

Cooling, heating and ventilation systems 3•9

10.7b Remove mounting bolts and

manoeuvre steering column mounting

bracket out of position

10.7a Release wiring connector from

steering column support bracket and

remove fusebox nut (arrowed)

10.5b . . . and disengage duct from heater

unit

10.13c . . . and withdraw matrix from

heater unit

10.13b . . . then remove cover . . .

10.12 Undo retaining screw and remove

matrix outlet pipe bracket

10.10b . . . and remove heater retaining

nuts

10.10a Disconnect wiring from heater

control panel . . .

10.9 Remove retaining stud and disengage

rear heater duct sleeve from heater unit

10.13a Undo two matrix cover retaining

screws . . .

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Heater blower motor

Heater blower motor resistor

21 Remove the glovebox as described in
paragraphs 15 and 16.
22 Disconnect the wiring connector, then
undo the two retaining screws and remove the
resistor from the front of the motor assembly.

Heater valve

23 Working in the engine compartment,
disconnect the cable inner from the heater

3•10 Cooling, heating and ventilation systems

10.20c Undo motor retaining bolts and

withdraw motor from unit

10.20b . . . and disconnect breather hose

10.20a Remove motor cover retaining

screws (arrowed) . . .

10.19b . . . and remove unit from behind

facia

10.19a Undo three blower motor mounting

bolts (arrowed) . . .

10.18 Disconnect motor wiring connec-

tors (A) and air recirculation cable (B)

10.17 . . . then remove blower motor-to-

heater unit duct

10.16 Remove glovebox support rail . . .

10.15 Glovebox damper retaining screw

(arrowed)

1689 Rover 214 & 414 Updated Version 09/97

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Rover 214-414. Service Repair Manual - part 5