Haynes Rover 200 Series Service and Repair Manual 1844252574, 9781844252572

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(01963) 442030 ¢ E-mail

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[email protected]

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www.haynes.co.uk

613 9763-8100

Illegal Copying It is the policy of Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms. of unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory authorities in whichever jurisdiction the offence takes place.

|

IAA 132hdhiadhie 8303

Rover 200 Series

Service and Repair Manual Spencer Drayton and Steve Rendle Models covered

(3399 - 368 - 12AH3)

Rover 211, 214, 216, 218 & 220 Hatchback models with petrol and turbo-diesel engines, including special/limited editions Petrol engines: 1.1 litre (1120 cc), 1.4 litre (1396 cc), 1.6 litre (1589 cc) & 1.8 litre (1796 cc) Turbo-diesel engines: 2.0 litre (1994 cc) Does not cover 200Vi models with 1.

NORTHUMBERLAND LIBRARY

COUNTY

30132013158303

629.2872

£17.99

ABODE

© Haynes Publishing 2005 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book transmitted in any form or by any mechanical, including photocopying, information storage or retrieval system, writing from the copyright holder.

may be reproduced or means, electronic or recording or by any without permission in

ISBN 1 84425 257 4

Bit EN dats Haynes Publishing Sparkford, Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes 4, Rue de I'Abreuvoir

92415 COURBEVOIE CEDEX, France

British Library Cataloguing in Publication Data

Haynes Publishing Nordiska AB

A catalogue record for this book is available from the British Library

Box 1504, 751 45 UPPSALA, Sweden

Contents LIVING WITH YOUR

ROVER 200

Introduction

Page

0294

Safety First!

Page

0e5

Roadside Repairs Introduction

Page

06

If your car won’t start

Page

0*6

Jump starting

Page

0Oe7

Wheel changing

Page

0e*8

Identifying leaks

Page

0e*9

Towing

Page

O29

Page

0°10

Page

0°10

Weekly Checks Introduction Underbonnet check points

‘

Engine oil level

Page

0e11

Power steering fluid level

Page

0Oe11

Brake fluid level

Page

0e12

Screen washer fluid level

Page

0e12

Coolant level

Page

0°13

Wiper blades

Page

0°13

Tyre condition and pressure

Page

0¢14

Battery

Page

0015

Electrical system

Page

0015

Lubricants, Fluids, Capacities and Tyre Pressures

Page 0°16

MAINTENANCE Routine Maintenance and Servicing Rover 200 petrol models

Page

1Ae¢1

Maintenance schedule

Page

1Ae93

Maintenance procedures

Page

1Ae5

Page

1Be1

Maintenance schedule

Page

1Be3

Maintenance procedures

Page

1Be5

Rover 200 diesel models

Illegal Copying It is the policy of Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms of unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory authorities.

Contents REPAIRS & OVERHAUL Engine and Associated Systems K-series petrol engine in-car repair procedures a e a a s Diesel engine in-car repair procedures

Page 2Ae1 ee Page 2Be1

Petrol engine removal and general overhaul procedures

Page

2Ce1

Diesel engine removal and general overhaul procedures

Page

2De1

Cooling, heating and ventilation systems

Page

3e1

Page

4Ae1

Fuel and exhaust systems - petrol engines

|

Fuel and exhaust systems - diesel engines

Page

4Be1

Emission control systems

Page

4Ce1

Starting and charging systems

Page

5Ae1

Ignition system - petrol engines

Page

5Be1

Pre-heating system - diesel engines

Page

5Ce1

Transmission Clutch

Page

6¢e1

Manual transmission

Page

7Ae1

Automatic transmission

Page

7Be1

Driveshafts

Page

8e1

Braking system

Page

9e1

Suspension and steering

Page

10e1

Bodywork and fittings

Page

11e1

Body electrical systems

Page

12¢1

Wiring Diagrams

Page 12°21

Brakes and Suspension

Body Equipment

REFERENCE Dimensions and Weights

Conversion Factors

Page

Page

REFe1

REFe2

Buying Spare Parts and Vehicle Identification

Page

REFe3

General Repair Procedures

Page

REFe4

Jacking and Vehicle Support

Page

REFe5

Radio/cassette Anti-theft System

Page

REFe5

Tools and Working Facilities

Page

REFe6

MOT Test Checks

Page

REFe8

Fault Finding

Page REFe12

Glossary of Technical Terms

Page REFe19

Index

Page REF*24

oe4 INtroduction

employing mechanical fuel injection, whilst 220Di and 220SDi modeis are fitted with a 105PS version of the same engine, employing an airto-air intercooler and electronic fuel injection. in 1989. At its launch in December 1995, the Rover 200 was available Two types of five-speed manual transmission are used; the PG1 unit in three and five door Hatchback body styles, powered by 1.4 litre . is fitted to diesel and 1.8 litre petrol models, with the RG665 unit fitted to eight-valve, 1.4 litre sixteen-valve and 1.6 litre sixteen-valve variants of the remainder of the range. The complete engine/transmission unit is the proven ‘K-series’ petrol engine. A range of diesei-engined models mounted transversely across the front of the car, with the transmission was launched at the same time, powered by two variants of the new mounted at the left-hand end of the engine. Drive to the front wheels is 2.0 litre turbocharged ‘L-series’ diesel engine. The range was extended via unequal-length, solid driveshafts. _ in 1997 by the inclusion of the 218 model, fitted with a 1.8 litre variant The front suspension incorporates coil-over-damper MacPherson ’_ of the sixteen-valve ‘K-series’ engine, and in 1998 by the addition of struts and an anti-roll bar. The hub carriers are located by tie rods and the 211 model, powered by a multi-point fuel injected, 1.1 litre variant single transverse lower arms. The rear suspension is of the torsionof the eight-valve ‘K-series’ engine. The flagship 200Vi model, fitted beam type, utilising coil-over-damper struts and tubular steel trailing with a 1.8 litre ‘K-series’ engine, featuring variable valve control (VVC), arms linked via a single twist beam axle. The whole assembly is bolted is not covered in this Manual. to the underside of the vehicle via composite rubber bushes and All petrol engined models are fitted with eight-valve, single overhead angled pivot mountings, which endow the car with ‘in-phase, passive camshaft or sixteen-valve double overhead camshaft versions of the ‘K’ rear steering’ for improved handling during cornering. Diesel and 1.8 series engine, controlled by the Rover/Motorola Modular Engine litre petrol models are also fitted with a rear anti-roll bar. Management System (MEMS) with multi-point fuel injection (MPi). All Braking is by discs at the front and drums at the rear, with a dualversions of the engine are able to accept a full range of emission control circuit hydraulic system. On all models in the range, an Anti-lock systems, up to and including a three-way regulated catalytic converter. Two derivatives of the ‘L-series’ turbocharged diesel engine are Braking System (ABS) was offered as an optional extra. Where ABS is available; 220D and 220SD models are fitted with an 86PS version, fitted, braking is by discs both at the front and rear. The Rover 200 Hatchback

model

covered

in this Manual

is an

evolution of the original Rover 214/216 Hatchback model first launched

Your Rover 200 Manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by. a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs, it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components, so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step

sequence. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver’s seat facing forward.

Acknowledgements Thanks are due to Draper Tools Limited, who supplied some of the workshop tools, and to all those people at Sparkford who helped in the production of this Manual. ROVER

Rover 211

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given.

Safety first! o-s Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

General hazards

Fume or gas intoxication

Scalding e Don’t remove the radiator or expansion tank cap while the engine is hot. e Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

Burning ¢ Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot

immediately after use.

Crushing e When working under or near a raised vehicle, always ERG supplement the jack with axle stands, or use

— [=

drive-on ramps. Never venture

® Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.

e Exhaust fumes are poisonous; they often contain carbon

Gee .

ci

monoxide, which is Bees rapidly fatal if inhaled. Never run the engine ina confined space such as a garage with the doors shut. ® Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.

Poisonous or irritant substances s!ig

FS

(Gag sin =)

e Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. e Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a

=

@ Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.

barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. e Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.

Fire

Asbestos

° Fuel is highly flammable; fuel vapour is

e Asbestos dust can cause cancer If inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.

eae

under a car which is only supported by a jack.

explosive.

© Don’t let fuel spill onto a hot engine. ¢ Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). e Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over an inspection pit. e Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. © Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.

Electric shock e Ignition HT voltage canbe

dangerous, especially to

és ng

the engine running or the ignition switched on.

Air bags e Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.

Diesel injection equipment e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes.

Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.

¢ Do use eye protection when using power

e Dont attempt to lift a Keay component: which may be beyond your pe os)get assistance.

tools, and when working under the vehicle. @ Do wear gloves or use barrier cream to — protect your hands when necessary.

.

@ Don’t rush to finish a job, or take unverified short cuts.

° Don't use ill-fitting tools which may slip

vehicle.

and cause injury.

© Do keep loose clothing and long hair well out of the way of moving mechanical parts.

where someone can trip over them. Mop

electrical system. e Do ensure that any lifting or jacking

5 j

e Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.

DON’T

e Do remove rings, wristwatch etc, before working on the vehicle — especially the

people with heart ff problems or a Ti pacemaker. Don’t ez work on or near the ignition system with

The battery

50.

that all is well when working alone on the

Pa +

Hydrofluoric acid e This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. e When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

Remember...

e Do get someone to check periodically

He

Special hazards

equipment has a safe working load rating adequate for the job.

e Don’t leave tools or parts lying around

up oil and fuel spills at once. ¢ Don’t allow children or pets to play in or near a vehicle being worked on.

o¢ Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters.

If your car won’t start even though the starter motor turns as normal

If your car won’t start and the starter motor doesn’t turn L] If it’s a model with automatic transmission, make sure the selector is in ‘P’ or ‘N’. ~ (1 Open the bonnet and make sure that the battery terminals are clean and tight. L} Switch on the headlights and try to start the engine. If the headlights go very dim when you’re trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend’s car.

Hees) A bad earth can cause intermittent problems in several circuits at the same time and can be difficult to trace. Check that the earth point bolts are secure and free from corrosion

Check

that

the

Is there fuel in the tank? Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. (Note that Diesel engines don’t normally suffer from damp.)

spark

plug

HT

lead

Check the security and condition of the battery connections

connections are clean and secure

The ECU wiring connector can cause problems if dirty, or poorly connected

=

Nt

ee

Check (with the ignition switched off) that all electrical connections are secure and spray them with a water-dispersant spray (such as WD40) if you suspect a problem due to damp

NECA

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