Rover 214-414. Service Repair Manual - part 6

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.

b)

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.

c)

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

d)

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

e)

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.

b)

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

c)

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

3

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

3

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 . . .

3

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

3

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.

b)

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

c)

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.

b)

Fit new O-rings to the pipe unions and

tighten the union nuts to the specified
torque setting.

c)

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

3

1689 Rover 214 & 414 Updated Version 09/97

1689 Rover 214 & 414 Updated Version 09/97

4A

Chapter 4 Part A
Fuel and exhaust systems - carburettor engines

Accelerator cable - removal, refitting and adjustment  . . . . . . . . . . .

9

Accelerator pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 10
Accelerator pedal switch - removal and refitting  . . . . . . . . . . . . . . . 11
Air cleaner air temperature control system - inspection and

component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Air cleaner assembly - removal and refitting . . . . . . . . . . . . . . . . . . .

3

Air cleaner filter element - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Carburettor - diagnosis, overhaul and adjustments  . . . . . . . . . . . . . 14
Carburettor - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Choke cable - removal, refitting and adjustment  . . . . . . . . . . . . . . . 12

Exhaust manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 17
Exhaust system - inspection, removal and refitting  . . . . . . . . . . . . . 18
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . .

7

Fuel pump - testing, removal and refitting  . . . . . . . . . . . . . . . . . . . .

6

Fuel system - inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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

1

Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 16
Inlet manifold pre-heater - operation, removal and refitting  . . . . . . . 15

4A•1

Contents

Specifications

Fuel pump

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

Mechanical, driven by eccentric on camshaft 

Carburettor

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

Hobourn-SU constant-depression/variable choke

Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KIF 44

Carburettor number:

Without catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAC 10004 or 10025

With catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAC 10011 or 10027

Throttle bore diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.0 mm

Piston spring colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Red

Damper  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LZX 2337

Jet size  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZX 2237 (0.100 in)

Needle identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BGZ

Needle valve seat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LZX 1756

Fast idle speed - at choke control first detent  . . . . . . . . . . . . . . . . . . . .

1200 rpm

Idle speed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 ± 50 rpm

CO level at idle speed - engine at normal operating temperature:

Without catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 to 3.0 %

With catalytic converter - at gas sampling pipe  . . . . . . . . . . . . . . . . .

1.0 to 3.0 %

Choke type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual

Recommended fuel

Minimum octane rating:

Without catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded (ie: unleaded Premium) or 97 RON leaded 
(ie: 4-star)

With catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded (ie: unleaded Premium)

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

5

4

3

2

1

1

General information and
precautions

General information

The fuel system consists of a fuel tank

mounted under the rear of the vehicle, a
mechanical fuel pump and a carburettor. The
fuel pump is operated by an eccentric on the
camshaft and is mounted on the rear of the
cylinder head. The air cleaner contains a
disposable paper filter element and
incorporates a flap valve air temperature
control system which allows cold air from the
outside of the vehicle and warm air from
around the exhaust manifold to enter the air
cleaner in the correct proportions.

The carburettor is the Hobourn SU-

manufactured KIF type, a development by
Rover of the previous HIF instrument. To
reduce emissions and to improve driveability
when the engine is cold, the inlet manifold is
heated by the cooling system coolant and by
an electric pre-heater system. Mixture
enrichment for cold starting is by a manually-
operated choke control.

The exhaust system consists of three

sections which are the front pipe and front
silencer box, the intermediate pipe and 
middle silencer box, and the tailpipe and main
silencer box. The system is suspended
throughout its entire length by rubber
mountings. If a catalytic converter is fitted, the
exhaust system consists of four sections, the
catalytic converter being situated between the
front pipe and the (much shorter) intermediate
pipe.

Precautions

Fuel warning

Many of the procedures in this Chapter

require the removal of fuel lines and

connections which may result in some fuel
spillage. Before carrying out any operation on
the fuel system, refer to the precautions given
in Safety first! at the beginning of this Manual
and follow them implicitly. Petrol is a highly
dangerous and volatile liquid and the
precautions necessary when handling it
cannot be overstressed.

Unleaded petrol - usage

The information given in this Chapter is

correct at the time of writing and applies only
to petrol currently available in the UK. If
updated information is required, check with a
Rover dealer. If travelling abroad, consult one
of the motoring organisations (or a similar
authority) for advice on petrol types available
and their suitability for your vehicle

The fuel recommended by Rover for the

214 and 414 models is given in Specifications,
followed by the equivalent petrol currently on
sale in the UK. RON and MON are different
testing standards. RON stands for Research
Octane Number (also written as RM); MON
stands for Motor Octane Number (also written
as MM, which is a different name for the same
octane scale).

All Rover 214 and 414 models are designed

to run on 95 (RON) octane petrol.
Super/Super Plus (unleaded) petrols can be
used without modification. If nothing else is
available, 4-star (leaded) petrol can only be
used if the vehicle is not fitted with a catalytic
converter. The only vehicles which must use
unleaded petrol at all times are those with
catalytic converters.

Catalytic coverters

Before attempting work on these items,

carefully read the precautions listed in Part D
of this Chapter. 

2

Air cleaner filter element -
renewal

Refer to Chapter 1.

3

Air cleaner assembly -
removal and refitting

2

Removal

1 Release the two clips securing the air intake
duct to the assembly, then undo the four
screws securing the assembly to its mounting
bracket.
2 Release the assembly from the intake duct
and withdraw it until the thermac switch
vacuum pipes can be reached. Make a note of
the correct fitted positions of the pipes to
ensure that they are correctly connected on
refitting (yellow to the temperature control
valve, red to the inlet manifold) then
disconnect them and withdraw the air cleaner
assembly (see illustration).
3 Check the condition of the O-ring around
the carburettor inlet and renew it if worn or
damaged.

Torque wrench settings

Nm

lbf ft

Fuel system

Carburettor retaining screws  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

7

Carburettor vent and air bleed pipe mounting nuts and bolts  . . . . . . . .

9

7

Needle retaining (grub) screw  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 to 2.3

1.3 to 1.7

Throttle disc retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.80 to 1.14

0.59 to 0.84

Fuel pump mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

7

Fuel tank hose retaining clip and union nuts  . . . . . . . . . . . . . . . . . . . . .

9

7

Manifold temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

Inlet manifold nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

Inlet manifold support stay bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

Exhaust system

Manifold retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Manifold shroud screws  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4

System flange nuts:

Manifold-to-front pipe joint  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

All other joints  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Front pipe mounting bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

4A•2 Fuel and exhaust systems - carburettor engines

3.2  Note colour-coding of thermac switch

vacuum pipes before disconnecting

1689 Rover 214 & 414 Updated Version 09/97

4 To remove the metal intake duct,
disconnect the vacuum pipe from the air
temperature control valve and slacken the
intake hose retaining clamp (see illustration).
Undo the fastener securing the duct to its
mounting bracket and remove the metal duct,
taking care not to lose the hot air intake
connector hose which connects the duct to
the exhaust manifold shroud.

5 To remove the air intake hose, it will first be
necessary to remove the left-hand headlamp
assembly so as to gain access to the two
retaining screws. Remove the retaining
screws securing the front of the hose to the
body front panel then release the clip securing
the ignition HT lead to the hose. If the metal
intake duct is still in position, slacken the hose
clamp then remove the hose from the engine
compartment.

6 A resonator chamber is fitted to the intake
hose to reduce the amount of induction noise.
To remove the chamber, first remove the
battery and battery tray. Disconnect the intake
hose and release any relevant retaining 
clips from the resonator then remove the
resonator from the engine compartment.

Refitting

7 Refitting is the reverse of the removal
procedure. Ensure that the vacuum pipes are
correctly reconnected and are not trapped as
the assembly is refitted, then check that the
assembly sits properly on the carburettor inlet
before tightening the screws securely.

4

Air cleaner air temperature
control system - inspection
and component renewal

2

Inspection

1 The system is controlled by a thermac
switch mounted in the air cleaner assembly.
When the engine is started from cold, the
switch is closed to allow inlet manifold
depression to act on the air temperature
control valve in the intake duct. This raises a
vacuum servo in the valve assembly and
draws a flap valve across the cold air intake,

thus allowing only (warmed) air from around
the exhaust manifold to enter the air cleaner.
2 As the temperature of the exhaust-warmed
air in the air cleaner rises, a bi-metallic strip in
the thermac switch deforms and opens the
switch to shut off the depression in the air
temperature control valve assembly. The flap is
lowered gradually across the hot air intake until,
when the engine is fully warmed-up to normal
operating temperature, only cold air from the
front of the vehicle is entering the air cleaner.
3 To check the system, allow the engine to
cool down completely, then slacken the intake
hose retaining clamp and disconnect the hose
from the metal intake duct. The flap valve in
the duct should be securely seated across the
hot air intake. Start the engine. The flap
should immediately rise to close off the cold
air intake and should then lower steadily as
the engine warms up, until it is eventually
seated across the hot air intake again.
4 To check the thermac switch, disconnect
the vacuum pipe from the control valve 
when the engine is running and place a finger
over the pipe end (see illustration). When the
engine is cold, full inlet manifold vacuum
should be present in the pipe. When the
engine is at normal operating temperature,
there should be no vacuum in the pipe.
5 To check the air temperature control valve,
slacken the intake hose retaining clamp and
disconnect the hose from the metal intake
duct. The flap valve should be securely seated

across the hot air intake. Disconnect the
vacuum pipe and suck hard at the control
valve stub. The flap should rise to shut off the
cold air intake.
6 If any component is faulty then it must be
renewed.

Thermac switch - renewal

7 Remove the air cleaner assembly.
8 Release the lid retaining clips then remove the
lid and withdraw the air cleaner filter element.
9 Bend up the tags on the switch clip and
remove the clip, then withdraw the switch and
its seal (see illustration).
10 Refitting is the reverse of the removal
procedure. Ensure that the switch mating
surfaces are clean and that the switch and
seal are correctly located before fastening the
clip.

Air temperature control valve -
renewal

11 Disconnect the vacuum pipe from the air
temperature control valve, then slacken the
intake hose retaining clamp and disconnect
the hose from the metal intake duct (see
illustration).
12 Release the two clips securing the air
intake duct to the air cleaner assembly and
undo the fastener securing the duct to its
mounting bracket. Withdraw the duct, taking
care not to lose the hot air intake connector
hose which connects the duct to the manifold
shroud (see illustration).

Fuel and exhaust systems - carburettor engines  4A•3

4.9  Thermac switch is clipped into air

cleaner assembly

4.4  Disconnect vacuum pipe from control

valve to check operation of system

components

3.4  Slacken clamp to disconnect intake

hose from air cleaner assembly metal

intake duct

4.12  Do not lose hot air intake connector

hose when removing air cleaner metal

intake duct

4.11  Disconnecting vacuum pipe from air

temperature control valve - intake hose-to-

metal intake duct securing clamp

(arrowed)

4A

1689 Rover 214 & 414 Updated Version 09/97

13 The air temperature control valve can be
renewed only with the complete intake duct
assembly. If a new intake duct assembly is
being fitted, undo the four screws securing
the hot air intake adaptor plate to the bottom
of the duct and transfer the adaptor plate to
the new duct.
14 Refitting is the reverse of the removal
procedure.

5

Fuel system - inspection

Refer to Chapter 1.

6

Fuel pump - testing, 
removal and refitting

2

Testing

1 To test the fuel pump on the engine,
temporarily disconnect the outlet pipe which
leads to the carburettor and hold a wad of rag
over the pump outlet while an assistant spins
the engine on the starter. Keep your hands
away from the electric cooling fan. Regular
spurts of fuel should be ejected as the engine
turns.
2 The pump can also be tested by removing
it. With the pump outlet pipe disconnected
but the inlet pipe still connected, hold a wad

of rag by the outlet. Operate the pump lever
by hand, moving it in and out. If the pump is in
a satisfactory condition, a strong jet of fuel
should be ejected.

Removal

3 Identify the pump inlet and outlet hoses
then, using a pair of pliers, release the
retaining clips and disconnect them from the
pump. Place wads of rag beneath the hose
unions to catch any spilled fuel and plug the
hose ends to minimise fuel loss (see
illustration).
4 Slacken and remove the nuts and washers
securing the pump to the cylinder head.
5 Withdraw the fuel pump from the engine
and remove the insulating block (see
illustration).

Refitting

6 Refitting is the reverse of the removal
procedure. Clean the mating surfaces and
renew the insulating block if its sealing
surfaces are marked or damaged. Tighten the
pump mounting nuts to the specified torque
wrench setting.

7

Fuel gauge sender unit -
removal and refitting

2

Removal

1 Disconnect the battery negative lead.
2 On 214 models, open the tailgate and
remove the parcel tray shelf. Fold the rear
seats fully forwards then raise the luggage
compartment carpet to gain access to the fuel
sender unit access cover.
3 On 414 models, open the boot lid and lift up
the luggage compartment carpet to gain
access to the fuel sender unit access cover.
4 On all models, undo the three screws and
remove the access cover from the floor (see
illustration).
5 Remove the sender unit wiring connector
rubber cover and disconnect the connector
from the sender.
6 Unscrew the sender unit retaining ring by
turning it in an anti-clockwise direction and
remove it from the fuel tank. In the absence of
the special Rover ring spanner, Service tool
number 18G 1595 (see illustration), a pair of
slip-jointed pliers will serve as an adequate
substitute to slacken the ring.
7 Carefully lift the sender unit, taking great
care not to bend or damage the sender float,
and remove the sealing ring. Examine the
sealing ring and renew it if it is worn or
damaged.

Refitting

8 Refitting is the reverse of the removal
procedure. Ensure that the tab on the sender
unit is correctly engaged with the cutout in the
fuel tank.

8

Fuel tank - 
removal and refitting

3

Warning: Do not under any
circumstances attempt to solder
or weld a fuel tank.

Removal

1 Before removing the fuel tank, all fuel must
be drained from the tank. Since a fuel tank
drain plug is not provided, it is therefore
preferable to carry out the removal operation
when the tank is nearly empty. Before
proceeding, disconnect the battery negative
lead and syphon or hand pump the remaining
fuel from the tank.
2 Chock the front wheels, then jack up the
rear of the vehicle and support it on 
axle stands. Remove the left-hand rear
roadwheel.
3 Undo the bolt then slacken and remove the
two screws securing the cover fitted to the
left-hand side of the fuel tank. Prise out the
screw retaining plugs and remove the cover to

4A•4 Fuel and exhaust systems - carburettor engines

7.6  Using Rover special tool to remove

fuel gauge sender unit

7.4  Undo three screws to remove fuel

gauge sender unit access cover

6.5  Removing fuel pump and insulating

block

6.3  Plug fuel hoses after disconnection -

pump inlet hose disconnected, outlet hose

arrowed

1689 Rover 214 & 414 Updated Version 09/97

gain access to the fuel tank feed and return
pipes (see illustration).
4 Using a suitable pair of pliers, release the
retaining clip and disconnect the small section
of return pipe hose from the fuel tank (see
illustration).
5 Slacken the fuel feed pipe union nut and
disconnect the pipe from the union. Undo the
two union mounting bolts and free the union
from the body (see illustration).
6 Disconnect the fuel tank wiring block
connector from the main wiring harness. If the
block connector cannot yet be reached, it
may be disconnected as the tank is lowered
out of position.
7 Slacken the clamp securing the filler neck
hose to the tank and use a pair of pliers to
release the filler neck breather pipe retaining
clip (see illustration). Disconnect both the
filler neck hose and breather pipe from the
fuel tank.
8 Release the fuel tank breather, situated
directly above the filler neck hose, from the
vehicle body.
9 Slacken the tank retaining strap locknuts,
then unscrew the lower locknuts and remove
the straps whilst supporting the tank (see
illustration).
10 Lower the fuel tank out of position and
remove it from under the vehicle.
11 If the tank is contaminated with sediment
or water, remove the sender unit and swill the
tank out with clean fuel. If the tank is
damaged or leaks, it should be repaired by a

specialist or alternatively renewed. Do not
under any circumstances attempt to solder or
weld a fuel tank.

Refitting

12 Refitting is the reverse of the removal
procedure. Tighten all nuts and bolts to their
specified torque wrench settings and ensure
that all hoses are correctly routed and
securely fastened so that there can be no risk
of fuel leakage.

9

Accelerator cable - removal,
refitting and adjustment

2

Removal

1 Unscrew the four windscreen wiper motor
mounting bolts to free the motor from the
engine compartment bulkhead.
2 Slacken the accelerator cable locknuts and
free the cable outer from its mounting bracket
on the carburettor. Release the cable inner
from the accelerator cam (see illustration).
3 Work back along the cable outer and
release it from any retaining clamps and ties.
4 Working from inside the vehicle, undo the
five right-hand lower facia panel retaining
screws and remove the panel.
5 Release the cable from the upper end of the
accelerator pedal and withdraw the cable
from the engine compartment.

Refitting

6 Refitting is the reverse of the removal
procedure. Tighten the windscreen wiper
motor retaining bolts to the specified torque
(Chapter 12). Prior to tightening the cable
locknuts, adjust the cable as follows.

Adjustment

7 Slacken both locknuts then gently pull up
on the cable outer until all free play is
removed from the cable and the accelerator
cam just starts to move.
8 Holding the cable in position, screw the
upper locknut down until there is a gap of
approximately 5.0 mm between the lower
edge of the nut and the cable mounting
bracket. Release the cable then have an
assistant depress the accelerator pedal fully
and check that the throttle opens fully and
returns to the at-rest position when the pedal
is released. If the throttle operation is correct,
hold the upper locknut stationary and tighten
the lower locknut securely.

10 Accelerator pedal - 

removal and refitting

2

Removal

1 Working from inside the vehicle, undo the
five right-hand lower facia panel retaining
screws and remove the panel.

Fuel and exhaust systems - carburettor engines  4A•5

8.5  Feed pipe union mounting bolts

(arrowed)

8.4  Fuel tank return pipe retaining clip (A)

and feed pipe union nut (B)

9.2  Disconnecting accelerator cable from

carburettor

8.9  Fuel tank mounting strap retaining

locknut

8.7  Slacken filler neck hose retaining

clamp (A) and disconnect breather pipe (B)

8.3  Removing cover retaining bolt

(arrowed) and screw retaining plugs

4A

1689 Rover 214 & 414 Updated Version 09/97

2 Release the accelerator cable from the
upper end of the pedal and, using a pair of
pliers, unhook the accelerator pedal return
spring.
3 Prise off the circlip from the pedal pivot and
withdraw the accelerator pedal from the
mounting bracket.

Refitting

4 Refitting is a reverse of the removal
procedure. Apply a smear of multi-purpose
grease to the pedal pivot. On completion,
adjust the accelerator cable.

11 Accelerator pedal switch -

removal and refitting

2

Removal

1 Working from inside the vehicle, undo the
five right-hand lower facia panel retaining
screws and remove the panel.
2 Using a suitable pair of pliers, unhook the
accelerator pedal return spring from the pedal
then disconnect the accelerator cable from
the pedal.
3 Disconnect the wiring connectors from the
accelerator pedal switch then prise off the C-
clip and remove the switch from the mounting
bracket. Note the wave washer fitted between
the switch and bracket.

Refitting

4 Refitting is a reversal of the removal
procedure.

12 Choke cable - removal,

refitting and adjustment

2

Removal

1 Remove the air cleaner assembly.
2 Free the choke cable outer from its
retaining clip on the carburettor and
disconnect the cable inner from the choke
cam (see illustration).
3 Work back along the cable outer and
release it from any retaining clamps and ties.
Prise the cable grommet out of the engine
compartment bulkhead.
4 Working inside the vehicle, undo the five
right-hand lower facia panel retaining screws
and remove the panel.
5 Using a suitable small screwdriver, slacken
and remove the choke knob grub screw then
pull the knob off the cable.
6 Unscrew the choke cable retaining nut then
release the cable from the facia and disconnect
the choke switch wiring connectors. The cable
can then be withdrawn from the engine
compartment and removed from the vehicle.

Refitting

7 Refitting is a reverse of the removal
procedure. On completion adjust as follows.

Adjustment

8 Have an assistant pull the choke control knob
fully out and check that the choke cam 
opens fully. Push the choke knob fully in and
check that the choke cam returns to the fully-off
position so that there is clearance between the
cam and the fast idle adjusting screw. Providing
that the choke cam returns fully, there should
be no free play present in the cable.
9 The cable is adjusted by releasing the
carburettor clip and repositioning the cable
outer.

13 Carburettor - 

removal and refitting

4

Removal

1 Remove the air cleaner assembly.
2 Slacken the accelerator cable locknuts and
free the cable outer from its mounting bracket
on the carburettor. Release the cable inner
from the accelerator cam.
3 Free the choke cable outer from its retaining
clip on the carburettor and disconnect the
cable inner from the choke cam.
4 Make a note of the correct fitted positions
of the two small bore vacuum pipes, to ensure
they are correctly positioned on refitting, then
disconnect them from the carburettor (see
illustration).
5 Using pliers, release the retaining clip and
disconnect the fuel feed hose from the
carburettor. Place wads of rag around the union
to catch any spilled fuel and plug the hose as
soon as it is disconnected to minimise fuel loss.
6 Make a note of the correct fitted positions
of the breather hoses then, where necessary,
release the retaining clips and disconnect the
three breather hoses from the carburettor.
7 Disconnect the wiring connector from the
carburettor idle bypass solenoid (see
illustration).
8 Unscrew the four Torx screws securing the
carburettor manifold adaptor to the inlet
manifold and remove the carburettor
assembly from the vehicle (see illustrations).
Remove the gasket and discard it, as a new
one must be used on refitting. Plug the inlet

4A•6 Fuel and exhaust systems - carburettor engines

13.8b  . . . and remove carburettor

assembly

13.8a  Unscrew upper-to-lower inlet

manifold Torx screws . . .

13.7  Note connections before

disconnecting idle bypass solenoid wiring

13.4  Breather hose (A), float chamber vent

and full load air bleed hoses (B), idle

bypass solenoid wiring (C) and fuel pump

outlet hose (D)

12.2  Releasing clip to disconnect choke

cable from carburettor - fast idle adjusting

screw arrowed

1689 Rover 214 & 414 Updated Version 09/97

port with a wad of clean cloth to prevent the
possible entry of foreign matter.

Refitting

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

Ensure the carburettor and inlet manifold
sealing faces are clean and flat. Fit a new
gasket and tighten the carburettor
retaining screws to the specified torque.

b)

Use the notes made on dismantling to
ensure all hoses are refitted to their
original positions and, where necessary,
are securely held by their retaining clips.

c)

Adjust the choke cable and accelerator
cables.

d)

Adjust the idle speed and mixture
settings.

14 Carburettor - diagnosis,

overhaul and adjustments

4

Diagnosis

1 The SU carburettor does not usually suffer
from jet blockages and wear is usually only
found between the needle and jet, although it
is worth checking the fit of the piston in the
suction chamber whenever the carburettor is
dismantled. If the idle speed is too high and
cannot be reduced by normal adjustment, it is
worth checking the throttle disc overrun valve
spring (if fitted). If this spring has weakened,
the throttle disc must be renewed.
2 If a carburettor fault is suspected, always
check first the following:
a)

That the ignition timing is accurate.

b)

That the spark plugs are in good condition
and correctly gapped.

c)

That the accelerator and choke cables are
correctly adjusted.

d)

That the carburettor piston damper is
topped-up.

e)

That the float chamber vent hose and
(especially if the mixture is very rich) the
full load air bleed hose are clear.

f)

That the air cleaner filter element is clean.

3 If the engine is running very roughly, check
the compression pressures, bearing in mind
the possibility that one of the hydraulic
tappets might be faulty, thereby producing an
incorrect valve clearance.
4 If careful checking of all of the above
produces no improvement, the carburettor
must be removed for cleaning and overhaul.

Overhaul

5 A complete strip-down of a carburettor is
unlikely to cure a fault which is not
immediately obvious without introducing new
problems. If persistent carburation problems
are encountered, it is recommended that the
advice of a Rover dealer or carburettor
specialist is sought. Most dealers will be able
to provide carburettor re-jetting and servicing
facilities and if necessary, it should be

Fuel and exhaust systems - carburettor engines  4A•7

14.8  SU KIF carburettor assembly

1

Piston damper

2

Suction chamber

3

C-clip

4

Piston

5

Piston spring

6

Needle retaining (grub)
screw

7

Needle spring

8

Needle

9

Needle guide

10 Idle speed screw
11 Spring
12 Idle speed adjusting knob
13 Throttle spindle seal
14 Screw
15 Throttle disc - with

overrun valve

16 Throttle spindle
17 Return spring
18 Fast idle lever
19 Lockwasher
20 Nut
21 Fast idle adjusting screw
22 Choke assembly
23 O-ring
24 Throttle return spring lever
25 Throttle lever
26 O-ring
27 Diaphragm
28 Idle air bypass screw
29 O-ring
30 Full load enrichment device
31 Spring
32 Idle bypass solenoid

33 Float pivot
34 Pivot seal
35 Carburettor body
36 O-ring
37 Jet adjusting screw
38 Fuel strainer
39 Float needle seat
40 Float needle
41 Float
42 Jet bearing
43 Jet bearing nut
44 Jet
45 Bi-metal lever assembly
46 Spring
47 Jet retaining screw
48 O-ring
49 Float chamber cover

4A

1689 Rover 214 & 414 Updated Version 09/97

possible to purchase a reconditioned
carburettor of the relevant type.
6 If it is decided to go ahead and service a
carburettor, check the cost and availability of
spare parts before commencement. Obtain a
carburettor repair kit, which will contain the
necessary gaskets, diaphragms and other
renewable items.
7 When working on carburettors, scrupulous
cleanliness must be observed and care must
be taken not to introduce any foreign matter
into components. Carburettors are delicate
instruments and care should be taken not to
disturb any components unnecessarily.
8 Referring  to the relevent exploded view of
the carburettor (see illustration on previous
page), remove each component part whilst
making a note of its fitted position. Make
alignment marks on linkages, etc.
9 Reassemble the carburettor in the reverse
order to dismantling, using new gaskets, O-
rings, etc. Be careful not to kink any
diaphragms.

Adjustments

Idle speed and mixture

10 Refer to Chapter 1.

Fast idle speed

11 Check the accelerator and choke cables
are correctly adjusted.
12 Warm the engine up to normal operating
temperature and check that the idle speed
and mixture are correctly set.
13 Pull out the choke control to the first
detent position and check that the engine
speed increases to the specified amount.
14 If adjustment is required, screw the fast
idle adjusting screw in or out until the engine
speed is correct.

Fuel level

15 The carburettor fuel level is adjusted by
bending the float arm to alter the float height,
usually measured with the carburettor
inverted. However, since the necessary
information is not provided by the
manufacturer, the vehicle should be taken to a
Rover dealer or SU carburettor specialist if the
fuel level is thought to be incorrect.

Jet adjustment

16 Accurate jet adjustment is not easy for the
inexperienced and can only be carried out
using an exhaust gas analyser. If the jet
adjustment is thought to be incorrect or is to
be checked, owners without the required
equipment and the skill to use it are advised
to have the work carried out by a Rover dealer
or SU carburettor specialist, otherwise
proceed as follows.
17 Warm the engine up to normal operating
temperature and check that the ignition
timing, idle speed and mixture are correctly
set and that the carburettor piston damper is
topped-up, see Chapter 1.
18 Remove the tamperproof cap from the jet
adjusting screw recess at the front left-hand
corner of the carburettor body.

19 Counting the exact number of turns
required to do so, screw the idle air bypass
screw clockwise until it seats lightly, then start
the engine, switch on the headlamps, heated
rear window and heater blower motor (first
speed only) and adjust the idle speed to 700
to 750 rpm.
20 Connect the exhaust gas analyser
following its manufacturer’s instructions.
21 Turning the jet adjusting screw either way
(clockwise to richen the mixture) by half a turn
at a time and waiting for the analyser reading
to respond and stabilise before making a
further alteration, set the mixture to a base CO
level of 5.5 % ± 0.5 %. When the analyser
reading is steady at the correct level, switch
off all electrical loads.
22 Screw the idle air bypass screw anti-
clockwise by the number of turns previously
noted to return it to its original setting, then
set the true idle mixture to the specified value.
23 Stop the engine when the adjustment is
correct, disconnect the test equipment and fit
a new tamperproof cap to the jet adjusting
screw recess.

Idle bypass system

24 As well as the carburettor idle air bypass
passage and screw, the system incorporates
the solenoid and the accelerator pedal switch.
25 When the accelerator is closed and the
ignition is switched on the solenoid is
energised, its plunger being retracted to open
the bypass passage. This allows air to bypass
the carburettor piston and thus makes the idle
mixture independent of the needle metering.
Screwing in (clockwise) the idle air bypass
screw reduces the amount of air bypassing
the piston and richens the idle mixture.
26 As soon as the accelerator pedal is
depressed, the accelerator pedal switch
opens, the solenoid is de-energised and the
bypass passage is shut off.
27 To check the system, listen closely by the
carburettor while an assistant switches on the
ignition and depresses and releases the
accelerator pedal several times. The solenoid
should be heard to be clicking in and out.
28 If no clicking is heard, remove the air cleaner
assembly and use a meter or similar to check
the solenoid earth and feed, see Chapter 12.

Use a meter to check that the accelerator pedal
switch contacts open and close. If the solenoid
or switch is faulty, then it must be renewed. Note
that if trouble is encountered with an ignition
system fuse blowing repeatedly, and the fault
cannot otherwise be traced, the solenoid may
be at fault.

15 Inlet manifold pre-heater -

operation, removal and
refitting

2

Operation

1 The system incorporates the manifold PTC
(Positive Temperature Coefficient) heater, the
relay and the manifold temperature switch.
2 When the ignition is switched on and the
engine is cold (coolant below 50°C), the relay-
energising current flows through the closed
manifold temperature switch contacts, which
then closes the relay contacts and allows
current to flow from the battery to the heater.
This ensures that the inlet manifold is warm
enough, even before the effect of the coolant
heating becomes apparent, to prevent fuel
droplets condensing in the manifold, thus
improving driveability and reducing exhaust
emissions when the engine is cold.
3 As soon as the engine warms up to
temperatures above 50°C, the switch
contacts open and the relay cuts off the
power supply to the manifold heater.
4 If the engine suddenly develops flat spots
when cold, the system may be faulty.

PTC heater

Removal

5 Drain the cooling system.
6 Apply the handbrake then jack up the front
of the vehicle and support it on axle stands.
Access to the PTC heater can then be gained
from underneath the vehicle, via the gap
between the engine and engine compartment
bulkhead.
7 Disconnect the wiring connector from the
heater terminal then extract the heater
retaining circlip. Withdraw the heater from the
underside of the manifold (see illustrations).

4A•8 Fuel and exhaust systems - carburettor engines

15.7b  . . . and remove PTC heater from

inlet manifold - manifold removed for

clarity

15.7a  Extract circlip . . .

1689 Rover 214 & 414 Updated Version 09/97

Inspect the heater rubber seal for signs of
damage or deterioration and renew if
necessary.

Refitting

8 Refitting is the reverse of the removal
procedure. Ensure that the heater locating
projection is correctly engaged in the manifold
recess. On completion, lower the vehicle to
the ground and refill the cooling system.

Pre-heater temperature switch

Removal

9 The pre-heater temperature switch is fitted
to the underside of the inlet manifold (see
illustration). Either drain the cooling system
or be prepared for some loss of coolant as the
switch is unscrewed.
10 Release the wire retaining clip and
disconnect the wiring connector from the
switch.
11 Unscrew the switch from the manifold 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.

Refitting

12 Wipe clean the threads of the switch and
of the thermostat housing. If a sealing washer
is fitted, renew it whenever it is disturbed to
prevent leaks. If no sealing washer is fitted,
apply a smear of sealant to the switch
threads.
13 Refit the switch, working quickly if the

cooling system was not drained, and tighten
it. Reconnect the wiring connector.
14 Replenish the cooling system.

Manifold heater relay

15 Refer to Chapter 12.

16 Inlet manifold - 

removal and refitting

3

Note: The following procedure describes
removal of the manifold with the carburettor.
Access to some of the components
concerned is much improved if the carburettor
is first removed separately and if this is done,
the following procedure should be amended
as required.

Removal

1 Disconnect the battery negative terminal.
2 Remove the air cleaner assembly.
3 Drain the cooling system.
4 Disconnect the accelerator and choke
cables.
5 Slacken the retaining clamps and
disconnect the coolant hoses from the inlet
manifold.
6 Trace the float chamber vent hose and the
full load air bleed hose from the carburettor
down to their metal pipes then unscrew the
nut and bolts securing the pipes to the
cylinder block/crankcase.
7 Using pliers, release the retaining clip and

disconnect the fuel feed hose from the
carburettor. Place wads of rag around the
union to catch any spilled fuel and plug the
hose as soon as it is disconnected to
minimise fuel loss.
8 Disconnect the vacuum pipe from the
distributor vacuum diaphragm unit and
disconnect the breather hose from the
cylinder head cover.
9 Slacken and remove the brake vacuum
servo unit hose union bolt and disconnect the
hose. Discard the hose union sealing washers
which must be renewed whenever they are
disturbed.
10 Disconnect the idle bypass solenoid
wiring, making notes of the connections so
that they can be correctly reconnected, then
disconnect the wiring from the manifold pre-
heater switch and heater which are situated
on the underside of the manifold.
11 Undo the single bolt which secures each
manifold support stay to the cylinder
block/crankcase and slacken the bolts which
secure the stays to the inlet manifold (see
illustrations).
12 Make a final check that all the necessary
fuel/breather hoses have been disconnected
from the carburettor/manifold then unscrew
the nuts and bolts securing the manifold 
to the cylinder head. Manoeuvre the 
manifold out of the engine compartment and
discard its gasket.

Refitting

13 Refitting is the reverse of the removal
procedure, noting the following (see
illustrations):
a)

Ensure that the manifold and cylinder

Fuel and exhaust systems - carburettor engines  4A•9

16.11b  Inlet manifold support stay lower

end bolt (arrowed)

16.11a  Inlet manifold support stay upper

end bolt (arrowed)

15.9  Inlet manifold pre-heater temperature

switch location

16.13c  Inlet manifold tightening sequence

- K8 engine

16.13b  . . . and fit inlet manifold - less

carburettor

16.13a  Fit a new manifold gasket . . .

4A

1689 Rover 214 & 414 Updated Version 09/97

head mating surfaces are clean and dry,
then fit a new manifold gasket.

b)

Working  in the sequence shown, tighten
the manifold retaining nuts and bolts
evenly to the specified torque wrench
setting.

c)

Ensure all relevant hoses are reconnected
to their original positions and are securely
held (where necessary) by their retaining
clips.

d)

Renew the vacuum servo unit vacuum
hose banjo union sealing washers and
tighten the union bolt.

e)

Adjust the accelerator and choke cables.

f)

On completion, refill the cooling system.

17 Exhaust manifold - 

removal and refitting

3

Removal

1 Disconnect the battery negative terminal.
2 Remove the air cleaner metal intake duct
assembly.
3 Firmly apply the handbrake then jack up the
front of the vehicle and support it on axle
stands.
4 Unscrew the nuts securing the exhaust
front pipe to the manifold, then disconnect the
pipe and collect the gasket.
5 Remove the four exhaust manifold shroud
retaining screws and remove the shroud.
6 Unscrew the nuts securing the manifold to
the cylinder head, then manoeuvre it out of
the engine compartment. Remove the
manifold gasket and discard it.
7 Examine all the exhaust manifold studs for
signs of damage and corrosion. Remove all
traces of corrosion and repair or renew any
damaged studs.

Refitting

8 Refitting is the reverse of the removal
procedure, noting the following (see
illustrations):
a)

Ensure that the manifold and cylinder
head sealing faces are clean and flat, then
fit a new manifold gasket.

b)

Working in the sequence shown, tighten
the manifold retaining nuts evenly to the
specified torque wrench setting.

c)

Tighten all other disturbed nuts and bolts
to their specified torque wrench settings
(where given).

18 Exhaust system - inspection,

removal and refitting

3

Note: If a catalytic converter is fitted to the
exhaust system, remember that it is FRAGILE.
Do not use hammers, mallets, etc. to strike
any part of the system and take care not to
drop it or strike the converter against anything
while handling it.

1 On models not equipped with a catalytic
converter the exhaust system is in three
sections. All exhaust sections are joined by a
flanged joint. If a catalytic converter is fitted, it
is situated between the front pipe and the

intermediate pipe, with a flanged joint at each
end. The front pipe then has a gas-sampling
take off point which is fitted to permit mixture
checks using an exhaust gas analyser (see
illustrations).

4A•10 Fuel and exhaust systems - carburettor engines

18.1a  Exhaust system components - without catalytic converter

1

Mounting rubber

2

Tailpipe

3

Nut

4

Heatshield

5

Bolt

6

Intermediate pipe

7 Mounting rubber
8 Nut
9 Gasket - front pipe to

intermediate pipe

10 Front pipe
11 Mounting rubber

12 Gasket - front pipe to

exhaust manifold

13 Nut
14 Bolt (stud replacement)
15 Plain washer

17.8b  Exhaust manifold tightening

sequence - K8 engine

17.8a  Refitting exhaust manifold with new

gasket

1689 Rover 214 & 414 Updated Version 09/97

2 The exhaust system is suspended
throughout its entire length by rubber
mountings 

(see illustration).

Inspection

3 Refer to Chapter 1.

Removal

4 Each exhaust section can be removed
individually or, alternatively, the complete
system can be removed as a unit once the
front pipe has been unbolted from the
manifold and the system has been freed from
all its mounting rubbers.
5 To remove the system or any part of the
system, first jack up the front or rear of the
vehicle and support it on axle stands.
Alternatively position the vehicle over an
inspection pit or on car ramps.

Front pipe

6 Remove the three nuts securing the front
pipe flange joint to the manifold and, where
necessary, the two bolts securing the front
pipe to its mounting bracket. Separate the
flange joint and collect the gasket (see
illustration).
7 Free the pipe from its mounting rubber then
undo the three nuts securing the front pipe to
the intermediate pipe/catalytic converter (as
applicable) and manoeuvre the front pipe out
from under the vehicle (see illustration).

Catalytic converter

8 Slacken and remove the two nuts securing
the catalytic converter to the intermediate
pipe, then separate the flange joint and
recover the gasket.
9 Undo the three nuts securing the converter to
the front pipe then remove it from the vehicle.

Intermediate pipe

10 Slacken the two nuts securing the tailpipe
flange joint to the intermediate pipe and
separate the flange joint.
11 Undo the three nuts securing the
intermediate pipe to the front pipe, or the two
nuts securing the pipe to the catalytic
converter (as applicable).
12 Free the intermediate pipe from all its
mounting rubbers and manoeuvre it out from
under the vehicle.

Fuel and exhaust systems - carburettor engines  4A•11

18.1b  Exhaust system components - with catalytic converter

1 Mounting rubber
2 Tailpipe
3 Nut
4 Heatshield
5 Bolt
6 Intermediate pipe
7 Mounting rubber
8 Nut
9 Gasket - catalytic converter

to intermediate pipe

10 Catalytic converter
11 Gasket - front pipe to

catalytic converter

12 Front pipe
13 Nut
14 Mounting rubber
15 Gas sampling pipe - open

loop system

16 Gas sampling pipe sealing

screw - open loop system

17 Blanking plug - closed

loop system

18 Gasket - front pipe to

exhaust manifold

19 Nut
20 Bolt (stud replacement)
21 Plain washer

18.7  Front pipe-to-intermediate pipe

flange joint and mounting rubber

18.6  Front pipe-to-manifold flange joint

18.2  Exhaust system rubber mounting

4A

1689 Rover 214 & 414 Updated Version 09/97

Tailpipe

13 Remove the two nuts securing the tailpipe
flange joint to the intermediate pipe and
separate the joint (see illustration).
14 Unhook the tailpipe from its three mounting
rubbers and remove it from the vehicle.
15 If the threads of the intermediate pipe to
tailpipe studs are damaged, or the studs snap
when the nuts are being undone, the studs
can be knocked out of position and replaced
with bolts.

Refitting

16 Each section is refitted by a reverse of the
removal sequence, noting the following:

a)

Ensure that all traces of corrosion have
been removed from the flanges.

b)

Renew all necessary gaskets.

c)

Inspect all rubber mountings for signs of
damage or deterioration and renew as
necessary.

d)

Tighten all flange nuts by hand only 
to locate the disturbed section in 
position, then ensure all exhaust 
system rubber mountings are correctly
seated.

e)

Check that there is adequate clearance
between the exhaust system and vehicle
underbody before tightening all flange
nuts to the specified torque.

4A•12 Fuel and exhaust systems - carburettor engines

18.13  Tailpipe-to-intermediate flange 

joint

1689 Rover 214 & 414 Updated Version 09/97

1689 Rover 214 & 414 Updated Version 09/97

4B

Chapter 4 Part B  Fuel and exhaust systems -
single-point fuel injection engines

Accelerator cable - removal, refitting and adjustment  . . . . . . . . . . . 11
Accelerator pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 12
Air cleaner assembly - removal and refitting . . . . . . . . . . . . . . . . . . .

3

Air cleaner air temperature control system - inspection and

component renewal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Air cleaner filter element - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Exhaust manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 18
Exhaust system - inspection, removal and refitting  . . . . . . . . . . . . . 19
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . .

9

Fuel injection system components - removal and refitting  . . . . . . . . 15

Fuel injection system components - testing  . . . . . . . . . . . . . . . . . . . 14
Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Fuel system - inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Fuel system - pressure check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . .

1

Inlet manifold pre-heater - operation, removal and refitting  . . . . . . . 16
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 17
Throttle housing - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 13

4B•1

Contents

Specifications

System

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

Rover/Motorola Modular Engine Management System, using ECU-
controlled single-point injection (MEMS-SPi) and speed/density
method of airflow measurement 

MEMS-SPi system data

Fuel pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric, immersed in fuel tank

Fuel pump pressure:

Maximum - at 16 volts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 bar

Regulated constant pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 to 1.2 bar

Injector/pressure regulator assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . .

JZX 3028

Throttle potentiometer voltage:

Throttle closed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 to 1 volt

Throttle open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 to 5 volts

Idle speed - nominal value given for reference purposes only  . . . . . . . .

850 ± 50 rpm

CO level at idle speed - engine at normal operating temperature:

Without catalytic converter - at tailpipe  . . . . . . . . . . . . . . . . . . . . . . .

0.5 to 2.0 %

With catalytic converter - at gas-sampling pipe  . . . . . . . . . . . . . . . . .

0.5 to 2.0 %

Recommended fuel

Minimum octane rating:

Without catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded (ie: unleaded Premium) or 97 RON leaded 
(ie: 4-star)

With catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded (ie: unleaded Premium)

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

5

4

3

2

1