Haynes Rover 2300 & 2600 Owners Workshop Manual 0856964689, 9780856964688

Citation preview

WE°

vA

Us

10 440 6737

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/rover230026000wn0000hayn

Rover

2300 & 2600 Owners Workshop 7H THRE TO

nual

IS A

i935

Ma

oe

IZS

OVD

Sian

WIR

LEVER

°-

bpepe|

by JH Haynes Member of the Guild of Motoring Writers

and P M Methuen Models covered: Rover2300 2350cc Rover2600 2597 cc Covers 4- and 5-speed manual gearbox and automatic versions of the above

ISBN

©

O 85696

468

9

Haynes Publishing Group

1980,

All rights reserved. No part of this book may

1982

be reproduced or transmitted

any form or by any means, electronic or mechanical,

recording or by any information storage or retrieval system, without in writing from the copyright holder.

Printed in England

\ WEST

(468 — 4H1)

in

including photocopying,

permission

ROY

Copy No.

4406737

I

HAYNES PUBLICATIONS INC 861 LA NEWBU CALIF USA

B

No,

7.

-

1GAG2RRR

'

ALERA

i

distributed in the USA by

ings

|]

Suppl er

HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET

| IDDADICA LIBRARIES

SUSSEX

+

HNN

ANOT

26./U6. 1983

Rd Re

Acknowledgements Thanks are due to BL Cars UK Limited (Rover Triumph Division) for their help in the provision of technical information and certain illustrations. The supply of technical information and illustrations by the Rover subsidiary of BL Cars UK Limited does not imply that the > . er subsidiary of BL Cars UK Limited has approved the contents of ook or is in any way responsible for the accuracy of any informa\ted. The copyright in illustrations and other technical material sd by the Rover subsidiary of BL Cars UK Limited remains in the Rover subsidiary of BL Cars UK Limited. 16 Champion Sparking Plug Company supplied the illustrations ing the various spark plug conditions. The bodywork repair

photographs used in this manual were provided by Lloyds Industries Limited who supply Turtle Wax’, ‘Dupli-Color Holts’ and other Holts range products. Castrol Limited supplied the lubrication data. Special thanks are due to F J Chalke and Son of Mere, Wiltshire, who were very helpful in providing technical information. Lastly, thanks are also due to all of those people at Sparkford who helped in the production of this manual; particularly Alan Jackson and Tony Steadman who carried out the mechanical work and took the photographs respectively, Stanley Randolph who planned the layout of each page and Chris Rogers who edited the text.

About this manual Its aim The aim of this manual is to help you get the best value from your car. 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 make use of the manual by tackling the work yourself. On simpler jobs it may be even quicker than booking the car into a garage, and having to go there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs the 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 step-by-step sequence so that even a novice can do the work.

sub-sections), with decimal numbers they are in, eg 5.1, 5.2, 5.3 etc.

following on from the Section

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration; figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the

Chapter: eg. Fig. 6.4 is the 4th drawing/illustration in Chapter 6. Photographs are numbered (either individually or in related groups) the same as Section or sub-section of the text where the operation they show is described. There is an alphabetical index at the back of the manual as well as a contents list at the front. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in a seat facing towards the front of the vehicle. Unless

otherwise

stated,

nuts and bolts are removed

by turning

/ts arrangement

anti-clockwise and tightened by turning clockwise. Whilst every care is taken to ensure that the information in this

The manual is divided into twelve Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into consecutively numbered Sections and the Sections into paragraphs (or

publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

manual

is correct

no liability can

be accepted

by the authors

or

Introduction to the Rover 2300 and 2600 The

October

Rover

2300

and

2600

SD1

models

were

introduced

in

1977, using the familiar bodyshell of the Rover 3500 SD1

which was introduced a year earlier. The two newer models replace the ageing Rover 2000 body style, although it had been re-vamped in

its later 2200 guise. In the BL Cars range these two new models also replace the Triumph 2000 and 2500. The six-cylinder engine fitted to the Rover 2300

and 2600

SD1

models is an entirely new design with several interesting features. The engine is basically the same for both models; the 2300 model has however a shorter stroke, thereby giving it a smaller cubic capacity.

But apart from the difference in crankshaft and pistons there is little else to separate them. The bodyshell of the two versions is the same 5-door hatchback

design. The fifth door lifts to reveal a very capacious boot area which can be increased still further when the luggage tray is taken out and the rear seat folded down. Its striking shape was evolved from extensive wind tunnel tests and has resulted in an aerodynamically nearperfect shape with very little drag. The 2600 model shares the same suspension as the Rover 3500,

whereas the 2300 has a slightly different type of damper system at the rear. There are other basic simplifications in the 2300 model which include the fitting of a 4-speed gearbox as standard and deletion of

some of the instruments and ‘extras’, such as warning lights in the rear edge of the front doors. Externally however, apart from the wheel trims and badges, they are identical. There are many optional extras which can be fitted to both models, although even the smaller engined 2300 model is very well appointed. These include a 5-speed gearbox for the 2300 model or automatic

transmission

for both models,

power steering for the 2300

model,

Dunlop Denovo wheels and tyres for both models, sunshine roof etc.

Comfort is of a very high standard and noteworthy is the rear seat arrangement, which has the comfort of any 4 or 5-seater saloon and is contoured although it folds flat to provide estate car type luggage

space. Safety and performance with economy in mind were all prime considerations during the design stage and the application of all these qualities make both the 2600 and 2300 SD1 models very exceptional cars.

Contents Page

Acknowledgements

2

About this manual

Pi

Introduction to the Rover 2300 and 2600

2

Safety first!

5

Quick reference chart

6

Buying spare parts and vehicle identification

numbers

74

Tools and working facilities

8

Jacking and towing

10

Recommended

na

lubricants and fluids

Routine maintenance

4

Chapter 1 Engine

14

Chapter 2 Cooling system

47

Chapter 3 Fuel and exhaust systems

53

Chapter 4

68

Ignition system

Chapter 5 Clutch Chapter 6 Manual

75 gearbox and automatic transmission

Chapter 7 Propeller shaft

81 99

Chapter 8 Rear axle

101

Chapter 9 Braking system

106

Chapter 10

118

Electrical system

Chapter

11 Suspension and steering

148

Chapter

12 Bodywork and fittings

160

Metric conversion tables

179

Index

181

The Rover 2300 SD1

The Rover 2600 SD1

Safety First! Professional motor mechanics are trained in safe working procedures. However enthusiastic you may be about getting on with the job in hand, do take the time to ensure that your safety is not put at risk. A moment's lack of attention can result in an accident, as can failure to observe certain elementary precautions. There will always be new ways of having accidents, and the following points do not pretend to be a comprehensive list of all dangers; they are intended rather to make you aware of the risks and to encourage a safety-conscious approach to all work you carry out on your vehicle.

Fire Remember at all times that petrol (gasoline) is highly flammable. Never smoke, or have any kind of naked flame around, when working on the vehicle. But the risk does not end there — a spark caused by an electrical short-circuit, by two metal surfaces contacting each other, or even by Static electricity built up in your body under certain conditions, can ignite petrol vapour, which in a confined space is highly explosive. Always disconnect the battery earth (ground) terminal before

working on any part of the fuel system, and never risk spilling fuel on

to a hot engine or exhaust. It is recommended that a fire extinguisher of a type suitable for fuel and electrical fires is kept handy in the garage or workplace at all

Essential DOs and DONTs DON'T

times. Never try to extinguish a fuel or electrical fire with water.

rely on a single jack when

working

underneath

the vehicle.

Always use reliable additional means of support, such as axle stands, securely placed under a part of the vehicle that you know will not give way. DON'T attempt to loosen or tighten high-torque nuts (e.g. wheel hub nuts) while the vehicle is on a jack; it may be pulled off.

Fumes

DON’T

should be done in a well ventilated area. When using cleaning fluids and solvents,

start the

engine

without

first ascertaining

that the trans-

mission is in neutral (or ‘Park’ where applicable) and the parking brake applied. DON'T suddenly remove the filler cap from a hot cooling system — cover it with a cloth and release the pressure gradually first, or you

Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Petrol (gasoline) vapour comes into this category, as do the vapours from certain solvents such as trichloroethylene. Any draining or pouring of such volatile fluids

carefully. Never use materials give off poisonous vapours.

as

to avoid scalding you. DON'T grasp any part of the engine, exhaust or catalytic converter without first ascertaining that it is sufficiently cool to avoid burning you.

open air or If you never drain is standing

DON'T

inhale brake lining dust — it is injurious to health.

DON'T allow any spilt oil or grease to remain on the floor — wipe it up straight away, before someone slips on it. DON'T use ill-fitting spanners or other tools which may slip and cause injury. DON'T attempt to lift a heavy component which may be beyond your capability — get assistance.

DON'T rush to finish a job, or take unverified short cuts. DON'T allow children or animals in or around an unattended vehicle. DO wear eye protection when using power tools such as drill, sander, bench grinder etc, and when working under the vehicle. DO use a barrier cream on your hands prior to undertaking dirty jobs — it will protect your skin from infection as well as making the dirt easier to remove afterwards; but make sure your hands aren't left slippery. DO keep loose clothing (cuffs, tie etc) and long hair well out of the way

of moving mechanical

DO

remove

parts.

rings, wristwatch

etc, before working on the vehicle —

especially the electrical system. DO ensure that any lifting tackle used has a safe working load rating adequate for the job. DO keep your work area tidy — it is only too easy to fall over articles

left lying around. DO get someone

to check periodically that all is well, when working

alone on the vehicle. DO carry out work in a logical sequence and check that everything is correctly assembled and tightened afterwards. DO remember that your vehicle's safety affects that of yourself and others. If in doubt on any point, get specialist advice. IF, in spite of following these precautions, you are unfortunate enough to injure yourself, seek medical attention as soon as possible.

unmarked

read the instructions containers — they may

Never run the engine of a motor vehicle in an enclosed space such a garage. Exhaust fumes contain carbon monoxide which is

may get scalded by escaping coolant. DON’T attempt to drain oil until you are sure it has cooled sufficiently

DON’T syphon toxic liquids such as fuel, brake fluid or antifreeze by mouth, or allow them to remain on your skin.

from

extremely poisonous; if you need to run the engine, always do so in the

at least have the rear of the vehicle outside the workplace. are fortunate enough to have the use of an inspection pit, or pour petrol, and never run the engine, while the vehicle over it; the fumes, being heavier than air, will concentrate

in the pit with possibly lethal results.

The battery Never

cause

a Spark, or allow

a naked

light, near

the vehicle's

battery. It will normally be giving off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery earth (ground) terminal before working on the fuel or electrical systems. If possible, loosen the filler plugs or cover when charging the battery from an external source. Do not charge at an excessive rate or the battery may burst. Take care when topping up and when carrying the battery. The acid electrolytes even when diluted, is very corrosive and should not be allowed to contact the eyes or skin. If you ever need to prepare electrolyte yourself, always add the acid slowly to the water, and never the other way round. Protect against splashes by wearing rubber gloves and goggles.

Mains electricity When using an electric power tool, inspection light etc which works from the mains, always ensure that the appliance is correctly connected to its plug and that, where necessary, it is properly earthed

(grounded). Do not use such appliances in damp conditions and, again, beware of creating a spark or applying excessive heat in the vicinity of fuel or fuel vapour.

Ignition HT voltage A severe electric shock can result from touching certain parts of the ignition system, such as the HT leads, when the engine is running or being cranked, particularly if components are damp or the insulation

is defective. Where

an electronic ignition system

voltage is much higher and could prove fatal.

is fitted, the HT

Quick reference chart Dimensions 2300/2600 SD1 models: Overall length cite ate b pevte tase etn

he eye inner ane cen

Overall width: < y-c:acaccSececeoieruptee 5ocak etiam on came oer Overall height’ 25.2. eters age ok ye ee dee epee oe ca Wheéelbase-y 6, ea eis ale, ck ao oS eee te Reee coe eee ae Track (frontand'réar) e. act cten tcl oe rece ee oneee Traek (With DenovotVres)m «cute ic ties meer ace ceedaera ret eas 2300 SD1

185 in (4699 mm) 69.6 in (1768 mm) 53.3 in (1354 mm) 110.8 in (2815 mm) 59.1 in (1500 mm) 58.7 in (1490 mm)

model:

GroundiclGarance es, oc aero. le pus chcrete mm ens a)Nea] aire emp tems ony 2600 SD1 model: GrOUNC CIOATANCE or. eis cis, o)onl cee MEER oe ee eae iis, eee nce

4.3 in (120 mm) 6.1 in (155 mm)

Kerb weights 2300 SD (iiodel «4 s.% 2 c.0/si0d sw sine a.Cee ZEOOSD TPmodeler kis oie «a wee

OR iets an anes or eee ei Pomeens ian neelaer eneteers

2899 |b (1315 kg) 2954 Ib (1340 kg)

Capacities 2300/2600 models: FUuGlitanigees Engine oil:

eee

eek shia

Was Ze Pe

am

teres

ne

Wihillterchatge 7.5 bce anh cont me aera cones Without filterchangedi... .» < Maan

tietay pecena aties let es

Sump.and filter capacity‘. ccgasvs.cls > diet cme ovum Sump (drain and refill) capacity

ta

a

clan

a

SAE 20/50 60 to 65 Ibf in? (4.22 to 4.57 kgf cm?) at 2000 rpm Holbourne-Eaton eccentric lobe, driven off front end of crankshaft Full-flow, disposable element

12.56 pints (7.1 litres)

nan

11.16

pints (6.3 litres)

Camshaft Hofer: tol aoe, - Who A meme Novof bearings. 5 s+ s...» x pate Wag. Diameter of journals Endtloatinicarior ...... 1h Ob rr cn Diameter of carrier bore Clearance in carrier Cam dwell period

Ce res Gen

er a ney gee gag eee

Right-hand side of camshaft carrier i

2.0079 to 2.0084 in (51.0 to 51.013 mm) ee

ey

ny

ee

0.002 to 0.006 in (0.050 to 0.144 mm)

2.0104 to 2.0114 in (51.063 to 51.090 mm) 0.002 to 0.003 in (0.050 to 0.090 mm) 235"

Z a

16 49 48

29 27 28 17 24 18 22 23

Chapter 1 Engine

15

Valve timing SO PRERE AESELTTBS NRC sre eT Amen ee odIhSua opsthier Siadoncadr-ai erGtiena) da Baio RENAE ASS ON TON ev pe des ot 9. GrOuasar FGD ySao akegart «AN OLX seea RUM NERUI ER EYSTIS insoe ve aes sive pend myACLs anehel + Pehl go Cina pe BED Sea EETEIRMRCESO OES Oh oe GEN ch us, baMaw ape A, 9).CEE TAT eR GLA, eacerbemn kesREN Oo),FoPade e Valve clearances: PTR aoe vente ete oe AMEE GAG 45)hy'b, nsrinpinadgtins st+ MEER Os Exhaust Timing marks: © TUTTE coupe Es isis ute wR IRS ra cia ie seie3 o-oo aaa Crankshaft

WZ" 52° 52° 12° 0.018 0.018

BIDE ABDC BBDC ATDC in (0.46 mm) in (0.46 mm)

Notch in drive pulley and notch in carrier Mark on crankshaft pulley and timing scale on oil pump cover

Valves Inlet (single spring): EC EREH METI PeE, GePix. aus Bile bar hasta. cayphn.joue end, aOR SGRGD yatne vee ae se RIE MALETENIES TGS cy

ME

Passe

hahha Ie oie, Hivjvaowh Coe ahiehere ode, hugpelm

Sa MACE MMT iii AIM N Gunns Pe. e's etsMesse boc dlagean |)-elallsiauy ace MUPESIMENIGS LO Memes. A's Saha! Pai eka twee bce sks. ou Wis ale aus o.al dane. veerang ERE CIGATONCE suv ahrens airiG feslee ese) o.suisehhhaus. «©. he 8 oy PROSE MM Peoria. coh bYOita moll) C naeh C eke vane RG. 481s) ke ep WUE MTNEINETOERIETICSEGL og cc ehnh 1 aruag ee acct CUETO ried.» Maye ad dsjane x oy STEM MMEEISNSS CCE

aechug37)4 9 avscms aiigne ok Oh

a.

OsCts

ge OURS a yentgae be

Exhaust (double springs): econ) [aeLG! GIR. canprdemneGries ane toon eatin ener a ee MEMEO LOR RG ce Re fides st ass! uty Were ILVigo Pe seers & a}Wie.a any og BaOEMS OTE ck GHGeie)o\i6>4 GREED Cred Fe sus ows aa, veHenares eo ack ek OK I TENG, GRRE cen thr See cs eR i oe PME O CIGATANCE. cistod cian.) esters 6 Ri aaa as as x cians Me AREER Ie gl he P Ea hans cade eee) mnt PO cate. uakras Spring free length: SERTEMELEWAIIG) iu. > seca ts.42 ap:cee aes 0 ovSMMC aires gre OMG sere Mayvare PAPOSESUIEANIC® «S15 g's 3.4 eRMREdt AIR SS als.a)aes Ac eens Bev miee age

4.636 to 4.654 in (117.75 1.653 in (42.00 mm)

to 118.20 mm)

45° 0.3107 to 0.3113 in (7.892 to 7.9307 mm) 0.0019 to 0.0012 in (0.05 to 0.03 mm)

1.820 in (46.25 mm) 1.62 in (41.15 mm) 1.3767 to 1.3772 in (34.968 to 34.980 mm)

4.649 to 4.665 in (118.09 to 118.54 mm) 1.4016 in (35.60 mm) 45° 0.3100 to 0.3106 in (7.874 to 7.889 mm) 0.002 to 0.0024 in (0.05 to 0.06 mm) 2.402 in (61.0 mm) 1.42 in (36.07 mm)

1.62 in (41.15 mm)

Rocker shafts On Tae ARE ee er Ake Soe Aer ee 8 oes arnt SMREM CER AITO LOT a. 6.s «,sus MG iouae o vichaicet as ecer Mathes ainda. vokig ge

0.747 to 0.748 in (18.987 to 19.0 mm)

0.749 to 0.750 in (19.025 to 19.043 mm)

Connecting rods PME LVUOOTH OCITICES © Ghani ly Kwaiebere 9.6.9 fore el nk eden eloleniire, Soa wi gs SAEBNC OUST INSIAE GiaMOtOl dicts viele 6 6 pe ne Oe 8 ae pdr ne oye

5.127 to 5.123 in (130.225 to 130.124 mm) 0.937 to 0.938 in (23.818 to 23.825 mm)

Big-end bearings IR: ty a ee ret om acece a Rach ne aa mee aeemer UE TTT AETA LICE 5 ins icee cate aie, = anes cA Cintas ee. hoa, Oat. one etalLivclient lnD(a] [Re es, Se Gee a a ee a ron ari erimn ar te MC Asin) vj nx 2)020 Guage to. PAM ce Goss oe tram aheteR ORDays

Vandervell 0.0027 to 0.001 in (0.068 to 0.025 mm) 0.005 to 0.013 in (0.16 to 0.34 mm) 0.020 in (0.51 mm)

Gudgeon pins re Ee AE Diameter

ih Sy or 51-7, 6.8“Ftc neue bansadunie traces

teste taint 2 ieato

2.626 to 2.638 in (66.70 to 67.00 mm) 0.937 to 0.9376 in (23.811 to 23.815 mm)

Clearance (push fit): RRP ec Ay cA bist salle « cts. bs + coe opm ee, + PRR PRCT MRMMS s Tta eye shen Xonys a % Gl ¥ QMpndoe vy wmackntv ste eae

Is aL s ReSES we

0.0003 to 0.0004 in (0.007 to 0.010 mm) 0.0003 to 0.0004 in (0.0067 to 0.0098 mm)

Pistons EAC MMM Seer: 7s Foe i win kn avSS Clearances: OGY) ee, ene ne Beer ESTEONT Lies ica ccd A

a

a

Meera ay PG

MRC CROCE RS yur tics5 MMT ie al.Ce ak eee ee areca anal aca eeeiniers eee ee ee eee etd

Aluminium alloy, strutted, by Mahle Aluminium alloy, W-slotted skirt type, by Hepworth and Grandage 0.177 to 0.024 in (0.450 to 0.613 mm) 0.0005 to 0.0015 (0.012 to 0.038 mm) 0.020 in (0.5 mm)

Piston rings MumDBrONe COMpPression sing TVPG

« ... +» « « « «dtleieatese wn newte ahenelpe

Memos tWO COMPression (NG TYPE»... nas a dined 6.5% ne Oe we Compression ring gap in bore: oT ae ey NE eer Rei ee heme 8 No 2 ring No 1 and No 2 compression ring to piston groove clearance ....... ERIE CUS VO 8 a A aati aul caus Viocs eee iaontan Gun ih a eS nbead

Chrome periphery Stepped ‘L’ shape marked ‘TOP’ on upper face

0.013 to 0.018 in (0.33 to 0.46 mm) 0.009 to 0.014 in (0.23 to 0.36 mm) 0.0019 to 0.0032 in (0.050 to 0.082 mm) 1 ring in 3 parts. A centre expander with an identical chrome rail above and below

Oil control ring gaps: 0.015 to 0.055 in (0.38 to 1.40 mm) Nil (the ends butt)

16

Chapter 1 Engine

eS

LL

Crankshaft Material Norof DEariMgS’ kirdeoves weave » ckene ce wll co ems aiere)ciel te Wstenets einen at ere Main journal diameter Minimuimiregrindidiameter: 2 tena sia ities Gree nien sian ens Crankbinijourmalidia meter ro ciq. wivncns eeem belie altetet nanan cea Minimumiregrindidiameter ~ 2 i.unctavcece cis cnet encimemenen napa suspoap re. Endthrust Endfloat Endfloat adjustment: Thrustwasher oversizesaVallable 3. ccc «un eieteienae le enreeniiels

EM 16 steel with induction hardened journals 4

2.768 to 2.771 in (70.311 to 70.3833 mm) 2.766 to 2.7685 in (70.260 to 70.3198 mm) 1.988 to 1.9885 in (50.4952 to 50.5079 mm) 1.9855 to 1.986 in (50.4317 to 50.4444 mm) Taken on thrustwashers on No 3 main bearing

0.003 to 0.011 in (0.076 to 0.279 mm)

0.002, 0.005, 0.010, 0.015 , 0.020 in (0.05, 0.127, 0.25, 0.379 mm)

Main bearings T'Wp@: "s/s: aiana eae scivenss yo) odie Number Undersize

Same RON cctesi ions Pagel athe tc Neue en mE

Vandervell, with numbered caps 4

0.20 in (0.51 mm)

Torque wrench settings

Ibf ft

Nm

96 75

130 102

Sy)

50

3 7 75 44 2A 52 147 30 an 2A

50 10 102 60 28 70 200 40 28 28

P| 7 10 30 2h 21 21 Px | 21

28 10 14 40 28 28 28 28 28 28

18 50

24 67

40.5

54

40.5

54

21 CW/ 25 35

28 50 34 52

Cylinder head bolts:

New Gasket age! ae a ste cusesuehster eno turartgs eusmea kon ea ee Tightening down Camshaft carrier bolts Gamshaftidnvepulley ris ce evaseicadietn. cucunuse tiene Cnn ceeeeiae ace Camshafticoverbattleiplatewnataat eres oracien. asters ayordcrs eieenee Main bearingicapi bolts: icra casa eee macnn +)otal mansions mien nee Big-end bearing Cap bolts. Giatc.c< eosreta « m tme wro seaemonie el cueeemene Clutch to flywheel

Flywheel (Driveplate) to crankshaft bolts Grankshaftipulley n.d Mapes tate photo susie, susaede Giri syraatossbans camuaberte Exhauistimamifold bolts Memmi