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Rover K Series 1.8 VVC Workbook

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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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  • Page 1 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.
  • Page 3 Introduction The 1.8 litre 16 valve ‘ K’ Series engine with Variable Valve control, (VVC), is available in the MG-F and the New Rover 200 series. The 1.8 litre VVC engine also employs the MEMs 2J Engine Management System The engine shares the key design features of the four cylinder ‘ K’ Series engine, with the ultra light, 'sandwich' construction of low pressure aluminium sand castings, held together by high tensile through bolts for strength and low distortion.
  • Page 4 Working within this basic restraint, Rover engineers were able to squeeze around 20% more power over the standard engine by varying the speed of the camshaft within each revolution;...
  • Page 5 ENGINE K SERIES 1.8 VVC Designing a working system for a 4 cylinder 16 valve engine was somewhat more complex! Accepting that all four pairs of camshaft lobes are positioned differently to cope with their unique role in the four stroke cycle, then each pair must be controlled with a degree of independence.
  • Page 6 ENGINE K SERIES 1.8 VVC VVC Technical Specifications Type ‘ K’ 1.8 VVC Bore 80.0mm Stroke 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.
  • Page 7 ENGINE K SERIES 1.8 VVC The following illustration shows the engine compartment components for the 1.8 VVC MG-F. Figure 5 1. Fuel filter 14. Manifold absolute pressure sensor 2. Resonator 15. Throttle cable 3. Fuel pump 16. Oil temperature sensor 4.
  • Page 8 ENGINE K SERIES 1.8 VVC The MEMS-2J, VVC Engine Control Module, (ECM), monitors all normal functions as with other engines, but with the ‘ variable valve control’ , the ECM controls the inlet valve opening and closing periods. • The ECM measures the cam period via the camshaft sensor, and also controls the VVC mechanism with two solenoids: one which increases the period and one which reduces the period.
  • Page 9 ENGINE K SERIES 1.8 VVC New Timing Belt (front) NOTE: When fitting a new timing belt, fit the spring pillar bolt and tensioner spring supplied with the new belt. After tensioning the timing belt, remove the spring and pillar bolt.
  • Page 10 ENGINE K SERIES 1.8 VVC Camshaft Drive Belt (Refit) • Ensure camshaft and crankshaft gears are clean and dry. • Correctly align the timing marks on camshaft gears then fit 18G 1570 to retain the camshaft gears in there correct position.
  • Page 11 ENGINE K SERIES 1.8 VVC Removal With the front timing belt cover removed, set the engine in its correct timed position, inserting special tool 18G 1570 to lock the front camshaft gears. • Using 18G 1521 to restrain the rear camshaft gear, loosen and remove both bolts securing each camshaft gear.
  • Page 12 ENGINE K SERIES 1.8 VVC Camshaft Oil Seals Front (Inlet) With the camshaft drive belt and camshaft gears removed: • Screw in gear retaining bolt to protect the threads in the camshaft. • To remove the oil seal. screw in special tool 18G 1299A into the oil seal, tightening the centre bolt of the special tool and extract the seal as shown.
  • Page 13 ENGINE K SERIES 1.8 VVC Figure 9 Cylinder Head For the purpose of this Training Workbook, and the relevant notes that follow, the engine is removed from the vehicle and is mounted on an engine stand in the workshop. The full procedure for removing the cylinder head whilst fitted in the vehicle can be found in the relevant Repair Manual.
  • Page 14 ENGINE K SERIES 1.8 VVC Figure 10 • With assistance, lift off the cylinder head from the cylinder block. CAUTION: Do not rotate the crankshaft with the 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.
  • Page 15 ENGINE K SERIES 1.8 VVC Cylinder Head (Dismantle) Camshaft End-float Before removing the camshaft carrier, check the camshaft end-float. This is done by fitting a suitable DTI to the camshaft carrier with the stylus contacting the face of number 4 front inlet camshaft lobe as shown.
  • Page 16 ENGINE K SERIES 1.8 VVC Camshaft Carrier (Remove) With the rear belt cover removed, use 18G 1521 located in the rear inlet camshaft gear, and rotate gear until the timing marks on both gears is facing outwards. NOTE: With the timing marks in this position, the cam-lobes of number 3,4,5 and 6 on the inlet camshafts should be facing upwards.
  • Page 17 ENGINE K SERIES 1.8 VVC • Carefully release the camshaft carrier from the cylinder head, then lift the carrier from the cylinder head complete with the VVC assemblies. • Ensure that both inlet camshafts are retained in the carrier, then invert the assembly •...
  • Page 18 ENGINE K SERIES 1.8 VVC Hydraulic Tappets Check the tappets for signs of wear, scoring and overheating, and ensure oil drilling in each tappet is free of restrictions. Figure 15 CAUTION: The hydraulic tappets fitted to the VVC engine are lighter than those fitted to non-VVC engines, and are similar in appearance to the earlier type tappets, (A), as shown.
  • Page 19 ENGINE K SERIES 1.8 VVC Figure 16 • Place a strip of Plastigage across each inlet camshaft journal, then carefully fit the carrier to the cylinder head, securing the carrier with the 32 bolts, (4 longer bolts at each end of carrier), and tighten in the sequence shown to 10Nm.
  • Page 20 ENGINE K SERIES 1.8 VVC NOTE: There are 2 different size journals on the inlet camshafts, 25mm and 40mm with different radial clearances. Inlet Camshaft Journal Clearances 25mm dia, = 0.025 to 0.060mm Service limit = 0.1mm 40mm dia. = 0.030 to 0.070mm Service limit = 0.1mm...
  • Page 21 ENGINE K SERIES 1.8 VVC VVC Housing Gaskets To replace the VVC housing gasket, one to each VVC assembly, lightly secure the front VVC housing and camshaft in a soft-jawed vice with the camshaft positioned upwards as shown. Figure 20 •...
  • Page 22 ENGINE K SERIES 1.8 VVC VVC Cylinder Head Data Maximum warp 0.05mm Cylinder head height: (New) 118.95 to 119.05mm Reface limit 0.20mm Valve spring colour code Blue Valve spring free-length 47.6mm Valve seat angle 45º Valve seat width 1.5mm Valve stem fitted height 38.93 to 39.84mm...
  • Page 23 ENGINE K SERIES 1.8 VVC Figure 22 Thoroughly inspect all components: • Piston bore and spool valve bore for scoring or corrosion. If heavy scoring or corrosion is apparent, the HCU will have to be replaced. NOTE: Light scoring and corrosion may be removed using 600 grade wet or dry paper, soaking the paper in engine oil for at least 30 minutes.
  • Page 24 ENGINE K SERIES 1.8 VVC • Fit new rack seal to plate, then slide rack through the seal. • Using fingers only, lubricate and fit new seal to piston, then secure the rack in the soft- jawed vice and fit piston to rack securing it with its screw.
  • Page 25 ENGINE K SERIES 1.8 VVC Cylinder Head Reassemble • Lubricate the exhaust cam lobes and journals with engine oil, and position camshaft in cylinder head, then lubricate the inlet camshafts and control shaft. • Position the control shaft into the carrier making sure the shaft is fully seated in its journals and the centre of the slot in the shaft is aligned with the cylinder head mating surface of the carrier.
  • Page 26 ENGINE K SERIES 1.8 VVC Figure 27 CAUTION: Make sure that the sealant is kept clear of oil feed drillings, oil grooves and control shaft journals and that assembly is completed within 20 minutes. It is also essential that during the following operations to ensure that the front and rear inlet camshafts are retained in the camshaft carrier and their respective VVC assemblies, and also taking great care not to rotate the camshafts or control shaft.
  • Page 27 ENGINE K SERIES 1.8 VVC • Make sure the piston is pushed fully to the top of the bore and that the rack teeth are aligned to the control shaft teeth, positioning the HCU and seal plate to the camshaft carrier, and making sure that the rack and control shaft teeth are engaged, then fit and finger tight the 3 bolts.
  • Page 28 ENGINE K SERIES 1.8 VVC • Fit new washer and oil temperature transmitter, then lubricate new ‘ O’ ring with engine oil and fit to camshaft sensor, install sensor to carrier and secure with bolt tightening bolt to 5Nm. The next stage of the operation is to fit the rear timing gears and drive belt, where 18G 1521 holding tool and a suitable straight edge are required.
  • Page 29 ENGINE K SERIES 1.8 VVC Cylinder Head - Refit If the crankshaft has been rotated, make sure that the timing mark on the crankshaft timing gear is aligned with the flange on the oil pump housing, and that 18G 1571 is locking the flywheel.
  • Page 30 ENGINE K SERIES 1.8 VVC • Fit the front belt upper rear cover and tighten bolts to 10Nm, then fit camshaft gears to their respective camshafts making sure that the camshaft drive gear pins, figure 33, are located in the correct slot...

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