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Workbook

Engine K Series 1.8 VVC

Rover Group are constantly seeking ways to improve the specification and design of its
vehicles and alterations take place continually.

Whilst every effort is made to produce up-to-date literature, this training workbook should
not be regarded as an infallible guide to current specification, nor does it constitute an
offer for the fitment of any particular system or component.

All rights reserved. no part of this Training Workbook may be reproduced without
prior permission of -

TECHNICAL ACADEMY

GAYDON TEST CENTRE

BANBURY ROAD

LIGHTHORNE

WARWICK

CV35 0RG

This Training Workbook is designed to support the Service Product Training courses and
is issued as part of the training programme.

It may be used to compliment other literature available but the Repair Operations Manual
should always be consulted prior to servicing or repair work.

© ROVER GROUP LIMITED - Nov 1997

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Содержание K Series 1.8 VVC

Страница 1: ...offer for the fitment of any particular system or component All rights reserved no part of this Training Workbook may be reproduced without prior permission of TECHNICAL ACADEMY GAYDON TEST CENTRE BA...

Страница 2: ......

Страница 3: ...ltra light sandwich construction of low pressure aluminium sand castings held together by high tensile through bolts for strength and low distortion The VVC engine also includes lightweight hydraulic...

Страница 4: ...whilst the valve is open to give a longer duration and speeding it up to give a snap open and close condition A Distance covered in first half of rotation B Distance covered in second half of rotatio...

Страница 5: ...ependent camshafts one for each pair of valves making four inlet camshafts in all As there is no direct drive between the two inlet camshaft assemblies an additional drive belt is used transmitting dr...

Страница 6: ...e 89 3mm Capacity 1796cc Compression ratio 10 5 1 Maximum power 147 PS 7000 rev min Maximum torque 174 Nm 4500 rev min Maximum rev min 7300 rev min The following graph shows the power and torque compa...

Страница 7: ...nition coil 5 Throttle position sensor 18 Fuel rail 6 Engine coolant temperature sensor 19 Idle air control valve 7 Intake air temperature sensor 20 Crankshaft position sensor 8 Camshaft position sens...

Страница 8: ...orrect special tools is the same for all 4 cylinder K series engines Camshaft Timing Belt NOTE It is important that the camshaft drive belt adjustment is carried out when the engine is COLD The front...

Страница 9: ...nes and must not be used on the VVC engine Figure 6 Camshaft Drive Belt Remove With the upper timing belt cover removed rotate crankshaft clockwise to align the timing marks on the camshaft gears and...

Страница 10: ...p gear making sure that the drive belt is central over all gears Fit the lower belt cover noting correct alignment of rubber dust seal and tighten cover bolts to 5Nm Fit crankshaft pulley tightening t...

Страница 11: ...lign the timing mark on the gear with the mark on the backplate Using finger pressure only fit exhaust camshaft gear and timing belt together ensuring that the gear is correctly aligned with the dowel...

Страница 12: ...g all traces of rubber are removed NOTE DO NOT scrape or lubricate the sealing areas Carefully position the new oil seal onto the camshaft Drift in new oil seal using 18G 1604 as shown making sure the...

Страница 13: ...ows greater manoeuvrability when lifting off and refitting the cylinder head Disconnect all cooling electrical and vacuum hoses making note of their fitted positions Remove the plenum chamber inlet an...

Страница 14: ...he cylinder head removed Fit cylinder liner clamps 18G 1736 securing the clamps with cylinder head bolts as shown ensuring that the bolts used are those originally fitted in that location Figure 11 Su...

Страница 15: ...igure 12 Push the camshaft fully rearward and zero gauge then move camshaft fully forward and note gauge reading Repeat the same procedure for the rear inlet camshaft with stylus contacting the face o...

Страница 16: ...hydraulic control unit HCU and withdraw the HCU from the cylinder head Figure 13 NOTE Remove and discard the 2 labyrinth seals and the rack seal from the seal plate and also taking care not to damage...

Страница 17: ...VVC assemblies then fit clamps 18G 1770 to both assemblies securing the clamps with the camshaft gear retaining bolts and washers CAUTION Identify each VVC assembly in its fitted position an DO NOT a...

Страница 18: ...nes 26 0 mm Later tappet Length VVC engines 24 5 mm Camshafts Inlet Inspection of the inlet camshafts on the VVC engine is the same as other K series engines except that the clamps 18G 1770 MUST NOT b...

Страница 19: ...quence shown to 10Nm Figure 17 CAUTION DO NOT rotate camshafts Progressively slacken and remove bolts then carefully remove camshaft carrier and VVC assembly from the cylinder head ensuring that both...

Страница 20: ...als is excessive fit new inlet camshafts with VVC assemblies and repeat process If clearances are still excessive renew cylinder head and carrier assembly Figure 19 Refit 18G 1770 clamps to both inlet...

Страница 21: ...ate to housing then fit the gasket aligning the bolt holes Assemble 18G 1770 clamp to the camshaft and VVC assembly retaining the clamp with gear bolt and washer then remove the assembly from the vice...

Страница 22: ...HCU If necessary the HCU can be dismantled to check the condition of the piston and spool valve bores for scoring or corrosion and the renewal of O rings To dismantle the HCU identify each solenoid t...

Страница 23: ...oil for at least 30 minutes Check the piston for scores and rack teeth for wear replacing the HCU if either are evident Check the control shaft gear teeth for wear or chipped teeth and renew if eithe...

Страница 24: ...w O rings and fit to the spool valve nut side of the inner solenoid and washer and bolt side of the outer solenoid Fit spool valve into HCU twisting the valve slightly as it is inserted into the bore...

Страница 25: ...ligned with the bolt holes in the carrier that the centre of slot in control shaft is still aligned with the carrier to cylinder head mating surfaces and timing plates 18G 1770 1 front and 18G 1770 2...

Страница 26: ...e 28 progressively tighten bolts to 10Nm Replace the slave bolts one bolt at a time retaining the VVC housings to the carrier with new Patchlock bolts Remove the timing plates from both VVC assemblies...

Страница 27: ...visible remove the HCU and carry out the following Figure 30 Using a screwdriver rotate the control shaft as far as possible in an anti clockwise direction figure 31 as viewed from the front of the ca...

Страница 28: ...k on the gears with the embossed line on the timing cover backplate Note With the timing marks in this position the inlet cam lobes of numbers 3 4 5 and 6 will be facing upwards Remove the inlet camsh...

Страница 29: ...ance fit cylinder head to block carefully locating the dowels then carefully enter cylinder head bolts in their original fitted locations DO NOT DROP into threads and screw in finger tight Figure 33 P...

Страница 30: ...inder block design features that accommodates the VVC cylinder head is similar to all 4 cylinder K Series engines These are Damp cylinder liners Lightweight aluminium alloy thermal expansion pistons V...

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