Rover 820, 825, 827. Repair Manual

Refitting

9 Refitting is a reversal of removal.

Heater blower motor

Removal

10 Remove the blower motor and housing
assembly from the car as described
previously.
11 Extract the clips securing the two halves
of the housing assembly, and lift off the upper
half.
12 Remove the separator plate.

13 Undo the nut and remove the fan from the
motor.
14 Disconnect the cooling hose and wiring
multiplug from the side of the motor.
15 Undo the motor retaining nuts, withdraw
the motor and collect the gasket.

Refitting

16 Refitting is a reversal of removal.

Heater matrix

Removal

17 Remove the facia as described in Chap-
ter 11.
18 Drain the cooling system as described in
Chapter 1.
19 From within the engine compartment,
disconnect the heater hoses at the matrix pipe
stubs.
20 Remove the duct between the heater
blower motor assembly and the matrix
housing. Collect the two seals.
21 Extract the retaining stud from the driver’s
side footwell duct and remove the duct (see
illustration).
22 Extract the two studs securing the rear
compartment duct to the matrix casing, and
slide the duct rearwards.

23 Remove the two retaining clips at the
base of the matrix housing.
24 Undo the two upper retaining bolts and
remove the matrix housing from the car (see
illustration).
25 Remove the seal from the top of the
housing.
26 Undo the screw and remove the left-hand
duct.
27 Release the clips around the upper face
aperture, and remove the face panel.
28 Release the clips securing the two halves
of the matrix housing, and separate the
housing.
29 Remove the matrix.

Refitting

30 Refitting is a reversal of removal.

Heater vacuum servo

Removal

31 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
32 Remove the trim panel under the facia on
the passenger’s side.
33 Open the glovebox, undo the two screws
securing the glovebox bar, and remove the
glovebox.
34 Disconnect the air duct from the side of
the heater blower assembly, and recover the
two seals.
35 Disconnect the vacuum hose at the servo
unit.
36 Extract the retaining spire clip, and
release the servo arm from the heater lever.
37 Undo the two screws and remove the
servo from the heater assembly.

Refitting

38 Refitting is a reversal of removal.

Heater solenoid valve

Removal

39 Proceed as described in paragraphs 31 to
34 above.
40 Disconnect the vacuum hose at the
solenoid valve.
41 Disconnect the solenoid wiring multiplug.
42 Undo the retaining screw and remove the
solenoid from the car.

Refitting

43 Refitting is a reversal of removal.

3•10 Cooling, heating and air conditioning systems

11.24 Matrix housing upper retaining bolts

(arrowed)

11.21 Exploded view of the matrix and housing assembly

1 Housing assembly
2 Clip
3 Blend lever

4 Distribution lever
5 Heater matrix
6 Duct

7 Duct
8 Duct
9 Duct joint

11.8b . . . and lower nut (arrowed)

1380 Rover 800 Series Remake

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12 Heater/air conditioning

controls -
removal and refitting

Heater control unit and cables

Removal

1 Remove the cowl around the instrument
panel as described in Chapter 12, Section 9.
2 Remove the trim panel under the facia on
the driver’s side.
3 Extract the outer cable retaining clips, and
slip the cable ends off the heater levers.
4 Withdraw the control unit and cables from
the facia.
5 Release the two inner and outer cables
from the control unit.

Refitting

6 Refitting is a reversal of removal. When
connecting the heater cables, adjust the
position of the outer cables in their retaining
clips so as to give full travel of the heater
levers, consistent with full travel of the control
levers.

Air conditioning control unit

7 Refer to “Instrument cowl switch units” in
Chapter 12, Section 4.

13 Air conditioning system -

general information and
precautions

General information

The air conditioning system consists of a

condenser mounted in front of the radiator, an
evaporator mounted adjacent to the heater
matrix, a compressor mounted on the engine,
a receiver/dryer, and the plumbing connecting
all of the above components (see
illustration).

A blower fan forces the warmer air of the

passenger compartment through the
evaporator core (rather like a radiator in
reverse), transferring the heat from the air to
the refrigerant. The liquid refrigerant boils off
into low-pressure vapour, taking the heat with
it when it leaves the evaporator.

Two versions of the system are used, the

change point being on models from
VIN 152206 onwards. Both versions are
virtually identical in component layout apart
from minor differences in the condenser pipe
connections. The main difference, however is
that the later version uses the more
environmentally friendly R134a refrigerant
whereas the early version uses the ozone-
depleting R12.

Precautions

Warning: The air conditioning
system is under high pressure.
Do not loosen any fittings or
remove any components until

after the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an approved type of
container, at a dealer service department
or an automotive air conditioning repair
facility capable of handling the refrigerant
safely. Always wear eye protection when
disconnecting air conditioning system
fittings.

When an air conditioning system is fitted, it

is necessary to observe the following special
precautions whenever dealing with any part of
the system, its associated components, and
any items which necessitate disconnection of
the system:
(a) While the refrigerant used on later models

- R134a - is less damaging to the
environment than the previously-used
R12, both are very dangerous substances.
They must not be allowed into contact
with the skin or eyes, or there is a risk of
frostbite. They must also not be

discharged in an enclosed space as there
is a risk of suffocation. The refrigerant is
heavier than air, and so must never be
discharged over a pit.

(b) The refrigerant must not be allowed to

come in contact with a naked flame,
otherwise a poisonous gas will be created
- under certain circumstances, this can
form an explosive mixture with air. For
similar reasons, smoking in the presence
of refrigerant is highly dangerous,
particularly if the vapour is inhaled
through a lighted cigarette.

(c) Never discharge the system to the

atmosphere - R134a is not an ozone-
depleting ChloroFluoroCarbon (CFC) as is
R12, but is instead a hydrofluorocarbon,
which causes environmental damage by
contributing to the “greenhouse effect” if
released into the atmosphere.

(d) R134a refrigerant must not be mixed with

R12; the system uses different seals and

Cooling, heating and air conditioning systems 3•11

13.1 Air conditioning system layout (V6 engine installation shown - 4-cylinder engine

installation similar)

1 Compressor
2 Condenser
3 Cooling fans (behind

radiator)

4 Receiver/drier
5 Evaporator

6 Thermostatic expansion

valve

7 Thermistor
8 Heater distribution and

blend unit

9 Blower unit

10 High and low pressure

servicing connections

11 High pressure switch
12 Dual pressure switch

1380 Rover 800 Series Remake

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has different fittings requiring different
tools, so that there is no chance of the
two types of refrigerant becoming mixed
accidentally.

(e) If for any reason the system must be

disconnected, entrust this task to your
Rover dealer or a refrigeration engineer.

(f)

It is essential that the system be
professionally discharged prior to using
any form of heat - welding, soldering,
brazing, etc - in the vicinity of the system,
before having the vehicle oven-dried at a
temperature exceeding 70ºC after
repainting, and before disconnecting any
part of the system.

14 Air conditioning system

components -
removal and refitting

Warning: Refer to the
precautions given in the
previous Section before
proceeding.

Condenser

Removal

1 Have the refrigerant discharged at a dealer
service department or an automotive air
conditioning repair facility.
2 Disconnect the battery negative (earth) lead
(see Chapter 5, Section 1).

3 On pre-1992 model year vehicles, remove
the radiator grille as described in Chapter 11,
Section 19.
4 Undo the two bolts each side securing the
centre platform to the body side members.
5 Undo the two nuts securing the condenser
to the front of the centre platform (see
illustration).
6 Undo the nut and retaining bolt securing
the bonnet safety catch to the centre
platform.
7 Cut off the cable ties securing the various
hoses to the centre platform.
8 Lift the centre platform upwards, turn it
over, and cut off the cable ties securing the
bonnet release cable to the platform
underside. Remove the platform from the car.
9 On early models, using two spanners, one to
unscrew the union nut and a second to
counterhold the relevant pipe, unscrew the pipe
unions on the front of the condenser. Where
fitted, recover the O-rings from the pipe unions.
Plug or cover the open pipes and condenser
ports. On later models, undo the two pipe union
retaining bolts and release the pipes. Recover
the O-rings from the pipe connector ends.
10 Undo the bolts from the pipe support
brackets and move the disconnected pipes
aside.
11 Lift the condenser upwards, and carefully
remove it from the car.

Refitting

12 Refitting the condenser is a reversal of

removal, but ensure that the lower mounting
lugs engage in the rubber grommets, and the
centre platform grommets locate over the
radiator upper lugs. Re-secure the bonnet
release cable and hoses to the centre
platform, using new cable ties. Have the
system evacuated, charged and leak-tested
by the specialist who discharged it.

Compressor - 4-cylinder engines

Removal

13 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
14 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
15 Raise the front of the vehicle and securely
support it on axle stands.
16 Remove the auxiliary drivebelt (see
Chapter 1).
17 Remove the alternator as described in
Chapter 5.
18 Undo the bolts securing the alternator
support bracket to the compressor and move
the support bracket aside.
19 Disconnect the compressor clutch wiring
at the in-line connector.
20 Unscrew the two pipe unions at the rear of
the compressor and plug or cover the
disconnected pipes and compressor ports.
Where fitted, recover the O-rings from the
pipe unions.
21 Undo the bolt securing the pipe bracket to
the flange on the underside of the
compressor.
22 Undo the upper and lower compressor
mounting nuts and bolts and remove the unit
upwards off the engine.

Refitting

23 Refitting the compressor is a reversal of
removal. Tighten the unions and mountings to
the specified torque. Have the system
evacuated, charged and leak-tested by the
specialist who discharged it.

Compressor - V6 engines

Removal

24 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
25 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
26 Raise the front of the vehicle and securely
support it on axle stands.
27 Remove the auxiliary drivebelt (see
Chapter 1).
28 Disconnect the compressor clutch wiring
at the in-line connector (see illustration).
29 Undo the four compressor mounting bolts
and withdraw the compressor from the
mounting bracket.
30 Undo the two bolts and release the pipe
mounting flanges from the compressor.
Recover the O-rings from the pipe unions and
plug or cover the disconnected pipes and
compressor ports.

3•12 Cooling, heating and air conditioning systems

14.5 Air conditioning condenser mounting and attachment details (early version shown)

1 Condenser-to-centre

platform retaining nuts

2 Centre platform
3 Pipe union nut

4 Pipe union nut
5 Pipe union nut
6 Bracket

7 Condenser
8 Lower mounting lug rubber

grommets

1380 Rover 800 Series Remake

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31 Working under the car, place a jack and
block of wood under the engine to support it,
then unscrew the eight bolts that secure the
engine longitudinal support member by
approximately 15 mm - it should not be
necessary to remove the bolts. Have an
assistant lever the support member down to
give increased clearance, which will allow the
compressor to be removed from the car.

Refitting

32 Refitting the compressor is a reversal of
removal. Tighten the unions and all mountings
to the specified torque. Have the system
evacuated, charged and leak-tested by the
specialist who discharged it.

Receiver/dryer

Removal

33 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
34 Unscrew the two pipe unions on top of
the receiver/dryer and plug or cover the
disconnected pipes and receiver/dryer ports
(see illustration). Recover the O-rings from
the pipe unions.
35 Undo the three mounting bolts, move the
adjacent components clear and remove the
unit from the car.

Refitting

36 Refitting the receiver/dryer is a reversal of
removal. Tighten the unions and mountings to
the specified torque. Have the system
evacuated, charged and leak-tested by the
specialist who discharged it.

Electric cooling fan assembly

37 Refer to Section 5.

Blower motor

Removal

38 Remove the trim panel under the facia on
the passenger’s side.
39 Disconnect the wiring multiplug from the
motor socket.
40 Detach the hose from the motor and
motor housing.
41 Undo the three bolts and remove the
motor from the blower housing.

Refitting

42 Refitting is a reversal of removal.

Evaporator

Removal

43 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
44 Undo the five screws and remove the
glovebox from the facia.
45 Remove the radio/cassette player and the
clock as described in Chapter 12.
46 Undo the retaining screws and remove
the glovebox bar.
47 From within the engine compartment
unscrew the two pipe unions using two
spanners, one to unscrew the union nut and a
second to counterhold the relevant pipe.
Recover the O-rings from the pipe unions. Plug
or cover the disconnected pipes immediately.
48 Disconnect the thermistor wiring multiplug
on the front face of the evaporator.
49 Undo the evaporator mounting nuts and
bolts, noting the location of any cable support
brackets and clips.
50 Disconnect the wiring at the connector
multiplugs as the unit is withdrawn and
remove the evaporator from the car.

Refitting

51 Refitting the evaporator is a reversal of
removal. Tighten the unions and mountings to
the specified torque. Have the system
evacuated, charged and leak-tested by the
specialist who discharged it.

Blower housing

Removal

52 Remove the evaporator as described
previously.
53 Disconnect the wiring multiplugs, undo the
mounting bolts and remove the unit from the car.

Refitting

54 Refitting is a reversal of removal.

Cooling, heating and air conditioning systems 3•13

14.28 Air conditioning compressor mountings and attachments on V6 engines

1 Tensioner pulley locknut
2 Tensioner adjuster bolt
3 Drivebelt

4 Wiring connector
5 Compressor mounting bolts
6 Compressor

7 Pipe mounting flange bolts
8 Mounting bracket bolts
9 Tensioner bracket bolt

14.34 Air conditioning receiver/dryer pipe unions (1) and mounting bolts (2)

1380 Rover 800 Series Remake

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1380 Rover 800 Series Remake

General

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indirect single-point injection with microprocessor control

ECU-controlled idle speed:

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 to 800 rpm

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

650 to 750 rpm

Base idle speed:

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

625 to 675 rpm

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

575 to 625 rpm

Idle mixture CO content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 to 3.0%

Throttle potentiometer voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

315 to 335 mV

Throttle lever lost motion gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5 to 0.9 mm

Fuel octane rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 RON leaded or 95 RON unleaded

Fuel Pump

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

Nippon Denso, electric

Output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 bar

Regulated pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 bar

Delivery rate (at 1.2 bar and 12 volts) . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 litres/hour

Voltage at pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.0 to 10.0 volts

Torque wrench settings

lbf ft

Inlet air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle body to manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank strap locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inlet manifold heater bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust front pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust section flange nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust heat shield retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 Part A: Fuel and exhaust systems –
Single-point injection engines

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

Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . .

Accelerator cable and linkage check and lubrication . . .See Chapter 1
Air cleaner assembly - removal and refitting . . . . . . . . . . . . . . . . . . .

Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Exhaust manifold - removal and refitting  . . . . . . . . . . .See Chapter 2A
Exhaust system - general information and component renewal . . . . 13
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . .

Fuel injection system - general information . . . . . . . . . . . . . . . . . . . 10

Fuel injection system - testing and adjustment  . . . . . . . . . . . . . . . . 11
Fuel injection system components - removal and refitting  . . . . . . . . 12
Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . .

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

Inlet manifold - removal and refitting . . . . . . . . . . . . . .See Chapter 2A
Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
Unleaded petrol - general information and usage . . . . . . . . . . . . . . .

4A•1

Specifications

Contents

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

General information and
precautions

The fuel system used on Rover 820e and

Se models consists of a centrally-mounted
fuel tank, electric fuel pump and single-point
fuel injection (SPi) system, together with its
related electrical and mechanical
components. A more detailed description of
the SPi system is contained in Section 10.

The exhaust system consists of a front,

intermediate and rear section, suspended
from the underbody on rubber mountings, and
bolted to a cast iron manifold at the front. A
ball-and-socket universal joint is incorporated
in the front section, to allow for engine and
exhaust system movement.

Precautions

Warning: Many of the
procedures in this Chapter
require the removal of fuel lines
and connections, which may

on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand. Before carrying out any operation
on the fuel system, refer also 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.

Reference must also be made to Chapter 5,

Section 1 for precautionary notes concerning
the ignition system and battery disconnection,
and to any further safety-related text
contained within the appropriate Section,
before working on the vehicle.

Certain adjustment points in the fuel system

are protected by tamperproof caps, plugs or
seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty.

When working on fuel system components,

scrupulous cleanliness must be observed and
care must be taken not to introduce any
foreign matter into the fuel lines or
components. The throttle body in particular is
a delicate instrument and care must be taken
not to disturb any components unnecessarily.
Before attempting work on the throttle body,

ensure that the relevant spares are available;
it should be noted that a complete throttle
body strip down is unlikely to cure a fault
which is not immediately obvious, without
introducing new problems. If persistent
problems occur, it is recommended that the
services of a Rover dealer or fuel injection
specialist is sought.

Air cleaner assembly -
removal and refitting

Note:

Air cleaner element renewal is

described in Chapter 1.

Removal

1 Slacken the hose clip securing the intake
trunking to the air cleaner body, and release
the HT cable from the support clip.
2 Undo the five upper bolts securing the air
box to the injector housing and support
bracket.
3 Lift up the air box, and disconnect the
wiring multiplug at the air temperature sensor,
and the vacuum hose at the fuel trap (see
illustrations).
4 Disconnect the vacuum hose from the inlet
manifold connection, and from the vacuum
motor on the air cleaner (see illustrations).
Remove the air box and intake trunking
assembly.
5 Undo the bolts securing the air cleaner
body and the forward air trunking assembly to
their support brackets (see illustrations). Lift

4A•2 Fuel and exhaust systems - single-point injection engines

2.5b . . . right-hand retaining bolt . . .

2.5a Undo the air cleaner body left-hand

retaining bolt (arrowed) . . .

2.4b . . . and at the vacuum motor

2.4a Disconnect the vacuum hose at the

inlet manifold . . .

2.3b . . . and disconnect the air

temperature sensor multiplug

2.3a Lift up the air box . . .

1380 Rover 800 Series Remake

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the body and trunking, disconnect the hot air
intake tube, and release the trunking from the
connecting duct at the front of the car.
Remove the air cleaner body and trunking.
6 If the cold air side intake is to be removed,
refer to Chapter 5, and remove the battery.
7 Undo the bolt securing the side intake to
the body, and remove the intake and duct
(see illustration).

Refitting

8 Refitting is a reversal of removal, but ensure
that all the ducts and trunking are fully
engaged before tightening the various
retaining bolts.

Accelerator cable - removal,
refitting and adjustment

Removal

1 Refer to Section 2 and remove the air
cleaner air box.
2 Unscrew the accelerator cable locknut
nearest to the cable end, pull the outer cable
upwards, and slide the inner cable out of the
slot in the support bracket (see illustration).
3 Release the inner cable end from the slot in
the throttle cam (see illustration).
4 From inside the car, release the turnbuckles
and lift out the trim panel over the clutch,
brake and accelerator pedals.

5 Prise the retaining clip from the top of the
accelerator pedal, and disconnect the inner
cable.
6 Release the cable from the engine
compartment bulkhead and from the support
clips, and withdraw the complete cable from
the car.

Refitting and adjustment

7 Refitting is a reversal of removal. Adjust the
cable initially by means of the outer cable
locknuts, to give a small amount of free play
with the throttle closed. On completion, check
the base idle speed as described in Sec-
tion 11.

Accelerator pedal -
removal and refitting

Removal

1 From inside the car, release the turnbuckles
and lift out the trim panel over the clutch,
brake and accelerator pedals.
2 Prise the retaining clip from the top of the
accelerator pedal, and disconnect the inner
cable from the pedal arm.
3 Undo the bolts securing the pedal bracket
to the bulkhead, and withdraw the bracket
and pedal assembly (see illustration).
4 Disconnect the switch wiring and remove
the bracket and pedal.

5 If the accelerator pedal switch is to be
removed, prise off the retaining C-clip and
remove the switch and washer.

Refitting

6 Refitting is a reversal of removal.

Fuel system -
depressurisation

Warning: Refer to the
precautions contained in
Section 1 before proceeding.

1 The fuel system referred to in this Chapter is
defined as the fuel tank and tank-mounted fuel
pump/fuel gauge sender unit, the fuel filter, the
throttle body, and the metal pipes and flexible
hoses of the fuel lines between these
components. Most of these contain fuel which
will be under pressure while the engine is
running and/or while the ignition is switched on.
2 The pressure will remain for some time after
the ignition has been switched off, and must
be relieved before any of these components
are disturbed for servicing or repair work.
3 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
4 Place absorbent rags around the fuel filter
outlet union banjo bolt, then slowly unscrew
the bolt to release the pressure (see
illustration).

Fuel and exhaust systems - single-point injection engines 4A•3

3.2 Undo the accelerator cable locknut . . .

2.7 Side intake to body retaining bolt

(arrowed)

2.5c . . . and the air cleaner trunking to

support bracket bolt (arrowed)

5.4 Place absorbent rags around the fuel

filter outlet union banjo bolt (arrowed),

then slowly unscrew the bolt to release the

system pressure

4.3 Accelerator pedal bracket retaining

bolts (arrowed)

3.3 . . . and release the cable end

(arrowed) from the throttle cam

1380 Rover 800 Series Remake

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5 Once the system pressure has been
completely relieved, tighten the banjo bolt and
dispose of the rags safely.

Fuel pump -
removal and refitting

Warning: Refer to the
precautions contained in
Section 1 before proceeding.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Release the fuel system pressure as
described in Section 5.
3 Remove the floor carpet from the luggage
compartment.
4 Refer to Chapter 11 and remove the rear
seats.
5 Release the eight studs and remove the
seat squab backing from the body.
6 Release the two studs and remove the
luggage compartment backboard from the
body.
7 Remove the cover board over the spare
wheel, and remove the tool kit.
8 Undo the four screws and lift off the pump
access panel (see illustrations). Move the
panel to one side.
9 Disconnect the pump wiring multiplug, then
unscrew the fuel hose banjo union bolt and
recover the copper washers (see illustration).

10 Slacken the clip and disconnect the fuel
return hose.
11 Undo the pump retaining nuts, and
withdraw the pump from the tank. Remove
the seal from the pump flange.

Refitting

12 Refitting is a reversal of removal, but
renew the flange seal if it shows any sign of
deterioration.

Fuel gauge sender unit -
removal and refitting

Warning: Refer to the
precautions contained in
Section 1 before proceeding.

Removal

1 Follow the procedure given in Section 6,
paragraphs 1 to 8 inclusive, with the
exception of paragraph 2.
2 Disconnect the two leads at the sender unit.
3 Engage a screwdriver, flat bar or other tool
with the lugs of the locking ring, and turn the
ring anti-clockwise to release it.
4 Withdraw the locking ring, seal and sender
unit.

Refitting

5 Refitting is a reversal of removal, but renew
the seal if it shows any sign of deterioration.

Fuel tank - removal,
inspection and refitting

Warning: Refer to the
precautions contained in
Section 1 before proceeding.

Removal

1 Follow the procedure given in Section 6,
paragraphs 1 to 8 inclusive.
2 Disconnect the fuel pump wiring multiplug,
and the two leads at the fuel gauge sender unit.
3 Remove the fuel tank filler cap.
4 With sealed containers handy, undo the
drain plug at the base of the tank, and drain
the fuel into the containers. Recover the drain
plug sealing washer. When all the fuel has
drained, refit the plug, using a new sealing
washer if necessary.
5 Chock the front wheels, remove the rear
wheel trim and slacken the wheel nuts. Jack
up the rear of the car and support it on axle
stands. Remove the left-hand rear roadwheel.
6 Slacken the retaining clip and disconnect
the filler hose from the filler neck. Move the
hose aside.
7 Slacken the retaining clips and disconnect
the five breather hoses from the breather
pipes.
8 Refer to Section 13 and remove the exhaust
system rear and intermediate sections,
together with the rear heat shield.
9 Slacken the retaining clip and disconnect the
fuel return hose from the pipe on the side of the
tank. Plug the disconnected pipe and hose.
10 Undo the union connector and disconnect
the fuel feed hose from the pipe. Plug the
disconnected pipe and hose.
11 Support the tank on a jack with
interposed block of wood.
12 Slacken the two tank retaining strap
locknuts, release the hook bolts from the
body slots, and move the straps clear (see
illustration).
13 Lower the tank and remove it from under
the car.
14 If the tank is contaminated with sediment or
water, remove the sender unit as described in
Section 7, and swill the tank out with clean fuel. If
the tank is damaged, or leaks, it should be
repaired by a specialist, or renewed. Do not
under any circumstances solder or weld the tank.

Refitting

15 Refitting is a reversal of removal.

Unleaded petrol - general
information and usage

Note: The information given in this Chapter is
correct at the time of writing, and applies only
to petrols currently available in the UK. If
updated information is thought to be required,
check with a Rover dealer. If travelling abroad,

4A•4 Fuel and exhaust systems - single-point injection engines

8.12 Fuel tank retaining strap and locknut

6.9 Fuel pump wiring multiplug connec-

tion (A) and fuel hose banjo union (B)

6.8b . . . and lift off the fuel pump access

panel

6.8a Undo the four screws (arrowed) . . .

1380 Rover 800 Series Remake

-------------------------------------------------------------------------------------------------------------------------------------------------------------

consult one of the motoring organisations (or a
similar authority) for advice on the petrols
available and their suitability for your vehicle.
1 The fuel recommended by Rover is given in
the Specifications at the beginning of this
Chapter, followed by the equivalent petrol
currently on sale in the UK.
2 RON and MON are different testing
standards.; RON stands for Research Octane
Number (also written as RM), while MON
stands for Motor Octane Number (also written
as MN).
3 All non-catalyst equipped 4-cylinder engine
models covered by this manual are designed
to run on leaded or unleaded petrols without
modification. Only unleaded petrol may be
used in those models fitted with a catalytic
converter.

10 Fuel injection system -

general information

The single-point fuel injection (SPi) system

is a microprocessor-controlled fuel
management system, designed to overcome
the limitations associated with conventional
carburettor induction (see illustration). This is
achieved by continuously monitoring the
engine using various sensors, whose data is
input to the fuel system Electronic Control
Unit (ECU). Based on this information, the
ECU program and memory then determine the
exact amount of fuel necessary, which is
injected into the throttle body by a single
injector, for all actual and anticipated driving
conditions.

The main components of the system and

their individual operation is as follows.

Fuel/ignition ECU: The fuel ECU is a

microprocessor which controls the injector
opening time, and therefore the amount of fuel
supplied. Contained in the ECU memory is a
program from which a pulse is derived, the
length of which determines the fuel injector
opening duration. Information received from
the various engine sensors will cause the ECU
to alter the fuel requirements, by changing the
pulse length. Airflow measurement is based
on the speed/density method, in which the
inlet air temperature and inlet manifold
pressure are measured under the assumption
that the engine is a calibrated vacuum pump,
with its characteristics stored in the ECU
memory. The air/fuel ratio requirements for all
engine speeds and loads are also stored in
the ECU. This information on the engine’s
basic fuel requirements is constantly
amended, according to the information
received from the various sensors. In addition
to this, the engine idle speed is also controlled
by the ECU, which uses a stepper motor to
open or close the throttle as required. Two
separate programs control the ECU functions.
One program operates under cruise
conditions, and the other at idle. The idle
program can be altered completely using

electronic test equipment, or partially by using
the procedures described in Section 11. Any
changes to this program do not affect the
cruise program, which cannot be accessed.
Whenever the battery is disconnected, the
idle program is lost, and the ECU reverts back
to a set of nominal parameters until the
information is reintroduced into the memory.
This can only be done using the
manufacturer’s test equipment, but the
performance of the engine at idle is only
marginally affected in this condition. As well
as control of the fuel injection system, the
ECU is also used to control the ignition timing.

Fuel injector: The single fuel injector is a

solenoid-operated ball valve, containing a fine
gauze filter and a nozzle with six spray holes
for complete fuel atomization. When a pulse is
received from the ECU, the injector sprays
fuel into the air stream through the throttle
body.

Throttle potentiometer: The potentiometer

is a variable resistor, attached to the throttle
shaft on the throttle body. The unit is supplied
with a constant input voltage, and as the
resistance of the potentiometer varies with
throttle shaft movement, the output voltage is
proportionally affected. This allows the ECU

to determine throttle valve position, and rate
of change.

Idle speed stepper motor: This is a small

electric motor, having four control windings to
enable it to rotate in either direction. Under a
signal from the ECU, the stepper motor will
rotate in whichever direction is necessary, to
open or close the throttle by means of
pushrod acting directly against the base idle
speed adjusting screw.

Inlet air temperature sensor: Located in

the airflow through the air cleaner air box, the
sensor is a thermistor (resistive device whose
resistance quickly decreases with
temperature increase).

Coolant temperature sensor:

This

resistive device is screwed into the thermostat
housing, where its element is in direct contact
with the engine coolant. Changes in coolant
temperature are detected by the ECU as a
change in the sensor resistance.

Ambient air temperature sensor: The

sensor is located behind the left-hand
headlight, and responds to changes in
ambient temperature with a corresponding
change in resistance.

Manifold heater: A manifold heater, to

improve atomization of the fuel/air mixture

Fuel and exhaust systems - single-point injection engines 4A•5

10.1 Main components of the single-point fuel injection system

1380 Rover 800 Series Remake

1 Ambient air

temperature sensor

2 Accelerator pedal

switch

3 Inlet air

temperature sensor

4 Throttle body and

idle speed stepper
motor

5 Fuel injector and

fuel pressure
regulator

6 Throttle

potentiometer

7 Main fuel system

relay

8 Fuel pump relay
9 Oil pressure relay
10 Coolant

temperature sensor

11 Manifold heater

temperature sensor

12 Manifold heater
13 Crankshaft sensor
14 Knock sensor
15 Inertia switch
16 Oil pressure switch
17 Fuel pump
18 Distributor cap and rotor

arm

19 Ignition coil
20 Diagnostic plug connector
21 Fuel/ignition ECU
22 Idle solenoid (models with

air conditioning)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

during warm-up conditions, is fitted to the
underside of the inlet manifold. The heater is
of the positive temperature coefficient (PTC)
type, in which the current consumption of the
heating element is high while it heats up, but
is greatly reduced at operating temperature.
The unit is controlled by a temperature
sensor, screwed into the coolant jacket of the
inlet manifold. When coolant temperature
reaches 50ºC, the sensor switches the
manifold heater off. To avoid a heavy drain on
the battery, current for the heater is supplied
via the oil pressure switch relay, and
consequently only switches on after the
engine has started.

Fuel pressure regulator: The fuel pressure

regulator is attached to the throttle body, and
maintains fuel pressure at a constant 1.0 bar.
When the pressure exceeds this value, the
regulator returns excess fuel to the tank via
the fuel return line.

Inertia switch: An inertia switch is fitted in

the ignition switch feed to the fuel pump relay,
and is situated inside the car behind the left-
hand side of the radio cassette player. In the
event of sudden impact, the switch trips out,
thus switching off the fuel pump relay. The
switch can be reset by pressing down the
reset button on the switch body.

Relays: The main fuel system relay is

energised when the ignition is switched on,
and supplies current to the ignition coil and
the fuel system ECU. The relay remains
energised for approximately five seconds after
the ignition is switched off, to enable the
stepper motor to cycle to the correct position
for engine starting. The fuel pump relay is
energised when the oil pressure relay is de-
energised by the low oil pressure switch.
When the engine is cranking, the fuel pump is
fed from the starter solenoid via the de-
energised fuel pump relay.

Fuel pump: The fuel pump is a self-priming

centrifugal unit, located in the fuel tank, and
totally submerged in the fuel. Fuel is supplied
under pressure from the pump, through a
non-return valve and in-line filter, to the fuel
pressure regulator, and then to the fuel
injector. The high capacity output of the pump
is reduced by a resistive wire in the harness
which reduces the supply voltage.

Accelerator pedal switch: When the

accelerator pedal is at rest, the pedal switch is
closed, and a signal is sent to the ECU
indicating that the engine is idling. On receipt
of this information, the ECU selects the idle
program from its memory, and automatic idle
speed control via the stepper motor is
implemented.

11 Fuel injection system -

testing and adjustment

Testing

1 If a fault appears in the fuel injection
system, first ensure that all the system wiring
connectors are securely connected and free
of corrosion. Then ensure that the fault is not
due to poor maintenance; ie, check that the
air cleaner filter element is clean, the spark
plugs are in good condition and correctly
gapped, the cylinder compression pressures
are correct, and that the engine breather
hoses are clear and undamaged, referring to
the relevant Sections of this Chapter, and to
Chapters 1 and 2 for further information.
2 If these checks fail to reveal the cause of
the problem, the vehicle should be taken to a
suitably equipped Rover dealer for testing on
Rover dedicated test equipment. This
equipment will locate the fault quickly and
simply, alleviating the need to test all the
system components individually, which is a
time-consuming operation that carries an
element of risk of damaging the ECU.

Adjustment

Engine tuning procedure

3 Before making any changes to the settings
of the fuel injection system, ensure that the
spark plug gaps are correctly set, the air
cleaner element is clean, there are no leaks in
the exhaust system, and the ignition system is
operating correctly. Ensure that all breather
and vacuum hoses are connected, and that
none are perished or kinked.
4 Temperature effects, and engine and
transmission oil drag, can adversely influence
the base idle speed setting, and it is important
that the following warm-up procedure is
adopted before attempting any adjustments.

5 Drive the car on the road for approximately
two to four miles, dependent on summer or
winter conditions, in a normal manner, without
excessive load, engine speed or road speed.
6 Return the car to the working area, switch
off and connect a tachometer, following the
equipment manufacturer’s instructions.
7 Start the engine again, and run it at
2000 rpm for ten seconds to stabilise the
mixture. The adjustment procedure described
in the following paragraphs can now
commence. If during the procedure the
cooling fan operates, or if adjustment is not
completed within two minutes, accelerate the
engine to 2000 rpm again, by means of the
throttle linkage (not the accelerator pedal) and
hold this speed for a further ten seconds.
Repeat this every two minutes until the
adjustments are completed.

Base idle speed and mixture
adjustment

8 The function of the fuel injection system is
such that the base idle speed and idle mixture
settings are controlled by the ECU, and of
these two, only the base idle speed can be
adjusted without the use of the
manufacturer’s test equipment. Should poor
idle quality be experienced, the base idle
speed should be checked, and if necessary
adjusted, using the following procedure. The
idle mixture setting will not normally require
attention unless the battery is disconnected,
in which case the settings in the ECU memory
will be lost. If the battery is disconnected for
any reason, the ECU can be recalibrated
using the procedure described in para-
graphs 21 to 28 as a temporary measure.
9 Refer to the engine tuning procedure above
before starting.
10 Switch off the engine, and ensure also
that all electrical circuits are switched off
throughout the procedure.
11 Undo the five bolts and lift off the air
cleaner box. Place the air box alongside the
engine, without disconnecting any of the
hoses or ducts.
12 Operate the throttle by hand, and check
that it opens fully and returns to rest against
the stepper motor pushrod.
13 Start the engine and using the throttle
linkage, not the accelerator pedal, increase
the engine speed to 1200 rpm, and hold it at
this speed. Check that the stepper motor
pushrod has retracted fully, then disconnect
the stepper motor multiplug (the round plug
on the side of the throttle body below the
accelerator cable).
14 Release the throttle and allow the engine
to stabilise at idle speed.
15 Check the engine base idle speed on the
tachometer, and compare the reading with the
figure given in the Specifications. If
adjustment is required, slacken the adjusting
screw locknut and turn the adjusting screw as
necessary to obtain the correct setting (see
illustrations). Tighten the locknut when the
speed is correct.

4A•6 Fuel and exhaust systems - single-point injection engines

11.15b . . . and turn the adjusting screw

(arrowed) to obtain the correct setting

11.15a Slacken the base idle speed

adjusting screw locknut . . .

1380 Rover 800 Series Remake

-------------------------------------------------------------------------------------------------------------------------------------------------------------

16 Check the lost motion gap by inserting a
feeler gauge of the specified size between the
forked end of the throttle lever and the peg on
the linkage. If the gap requires adjustment,
slacken the accelerator cable locknuts and
reposition the outer cable until the correct
setting is achieved (see illustrations). Tighten
the locknuts when the gap is correct.
17 Reconnect the stepper motor multiplug.
18 Switch off the ignition, wait three seconds
and switch the ignition on once more. After a
further three seconds, switch off the ignition
again. The stepper motor will now be in the
correct position for the next engine start.
19 On cars equipped with automatic
transmission, refer to Chapter 7, Part B and
check the kickdown cable adjustment.
20 Refit the air cleaner air box and
disconnect the tachometer on completion.

Electronic control unit calibration

21 As previously stated, whenever the
battery is disconnected, the idle mixture
setting stored in the ECU memory will be lost.
On reconnection of the battery, the following
procedure may be used to recalibrate the unit
temporarily, until such time as the car can be
taken to a dealer for accurate setting on Rover
dedicated test equipment.
22 Run the engine with all electrical circuits
switched off, until the engine cooling fan
operates then stops.
23 Switch off the engine immediately the
cooling fan stops.
24 Switch the ignition on to position two of
the key.

25 Depress the accelerator pedal through at
least half its travel, then release it, five times.
26 Wait until the high engine temperature
warning light starts to flash.
27 As soon as the high engine temperature
warning light stops flashing, start the engine
without depressing the accelerator pedal,
and allow it to idle. If the accelerator pedal is
depressed, or if an electrical unit is switched
on, the calibration will cease. (This also
applies to the interior lights operated by the
door pillar switches, so keep the doors
closed).
28 Wait for two to three minutes until the
warning light flashes again, indicating that
calibration is complete.

12 Fuel injection system

components -
removal and refitting

Note: Refer to the precautions contained in
Section 1 before proceeding.

Thermac switch

Removal

1 Refer to Section 2 and remove the air
cleaner air box.
2 Disconnect the two vacuum hoses at the
thermac switch on the base of the air box (see
illustration).
3 Remove the air box intake trunking for
access to the switch.
4 Carefully prise off the switch retaining clip,
and remove the switch from inside the air box.

Refitting

5 Refitting is a reversal of removal, but
position the unit so that the large diameter
pipe is towards the air temperature sensor.
Connect the vacuum hose from the manifold
to the pipe with the small diameter hole, and
the vacuum hose from the air cleaner vacuum
motor to the pipe with the large diameter hole.

Inlet air temperature sensor

Removal

6 Refer to Section 2 and remove the air
cleaner air box.
7 Unscrew the sensor from the adaptor on
the base of the air box. If the adaptor
unscrews with the sensor, unscrew the
adaptor and refit it to the air box.

Refitting

8 Refit the sensor to the adaptor, and refit the
air box.

Throttle potentiometer

Removal

9 Refer to Section 2 and remove the air
cleaner air box.
10 Disconnect the multiplug from the side of
the potentiometer body.
11 Using a dab of paint, mark the position of
the throttle potentiometer in relation to the
mounting adaptor.
12 Undo the two screws, remove the
potentiometer, and lift off the adaptor (see
illustration).

Refitting

13 Refitting is a reversal of removal. Ensure that
the potentiometer lever engages to the right of
the throttle lever, and align the previously-made
mark before tightening the retaining screws.
Have the potentiometer position adjusted
accurately by a Rover dealer on completion.

Injector housing

Removal

14 Relieve the fuel system pressure as
described in Section 5.
15 Refer to Section 2 and remove the air
cleaner air box.
16 Using pliers, release the two fuel hose
retaining clips at the injector housing, and
disconnect the two hoses (see illustration).
Plug the hoses after removal.

Fuel and exhaust systems - single-point injection engines 4A•7

12.2 Thermac switch vacuum hoses

(arrowed)

11.16b . . . and adjust the lost motion gap

at the accelerator cable

11.16a Insert a feeler gauge between the

throttle lever and peg . . .

12.16 Release the two fuel hose retaining

clips at the injector housing, and

disconnect the two hoses

12.12 Throttle potentiometer retaining

screws (A) and adaptor (B)

1380 Rover 800 Series Remake

-------------------------------------------------------------------------------------------------------------------------------------------------------------

17 Disconnect the injector wiring multiplug.
18 Undo the four screws securing the
injector housing to the throttle body, and lift
off the housing (see illustration). The housing
may be initially tight, due to the two locating
dowels. Recover the gasket from the throttle
body.
19 This is the limit of dismantling that can be
undertaken on the injector housing assembly.
Should it be necessary to renew the fuel
injector or fuel pressure regulator, a complete
injector housing assembly must be obtained.
20 Clean the mating faces of the injector
housing and throttle body, and remove all the
old locking compound from the threads of the
retaining screws. Obtain a new gasket if the
original shows any signs of deterioration.

Refitting

21 Place the gasket in position on the throttle
body, and locate the injector housing over the
gasket.
22 Apply a thread-locking compound to the
four retaining screws, then fit and tighten the
screws securely.
23 Reconnect the injector wiring multiplug.
24 Reconnect the two fuel hoses, then locate
the retaining clips 3.0 mm from the hose ends.
25 Refit the air cleaner air box, then adjust
the engine base idle speed as described in
Chapter 1.

Stepper motor unit

Removal

26 Remove the injector housing as previously
described.
27 Disconnect the wiring multiplug from the
side of the stepper motor.
28 Undo the four outermost screws that
secure the stepper motor to the throttle body
(see illustration). Do not remove the two
screws near the centre of the unit.
29 Lift off the accelerator cable support
bracket, with cable still attached, and place it
to one side.
30 Carefully lift off the stepper motor unit
and, where fitted, recover the gasket (see
illustration). Note that the gasket was only
fitted to early models, and if present, discard
it, and do not fit another on reassembly.

31 Clean the components with a clean cloth,
and remove all the old locking compound
from the threads of the retaining screws.

Refitting

32 Refitting is a reversal of removal, but use a
thread-locking compound on the retaining
screw threads.

Throttle body

Removal

33 Remove the injector housing as previously
described.
34 Disconnect the wiring multiplugs to the
stepper motor and throttle potentiometer.
35 Disconnect the two breather hoses on the
side of the throttle body (see illustration).
36 Slacken the accelerator cable locknuts,
open the throttle fully and slip the cable end
out of the throttle cam. Unscrew the lower
cable locknut fully, and remove the
accelerator cable from the support bracket.
37 On automatic transmission models,
disconnect the kickdown cable, using the
same procedure as for the accelerator cable.
38 Undo the four nuts securing the throttle
body to the manifold.
39 Lift off the throttle body, and recover the
manifold spacer, with gaskets.
40 Clean the mating faces on the manifold
and throttle body, and renew the gaskets on
the spacer if they show any sign of
deterioration. If the gaskets are being
renewed, attach them to the spacer using
non-drying jointing compound.

Refitting

41 Place the spacer with gaskets over the
manifold studs, then place the throttle body in
position. Secure the throttle body with the
four nuts tightened securely.
42 Reconnect the breather hoses and the
wiring multiplugs.
43 Refit the accelerator cable and adjust it,
by means of the locknuts, to give a small
amount of free play in the throttle-closed
position.
44 On automatic transmission models, refit
and adjust the kickdown cable as described in
Chapter 7, Part B.
45 Refit the injector housing as described
previously.

Electronic control unit (ECU)

Removal

46 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
47 Disconnect the wiring multiplug from the
ECU, which is located on the left-hand side of
the engine compartment behind the battery.
To do this, press the retaining tab upwards,
release the bottom of the multiplug, then
disengage the top lug (see illustration).
48 Disconnect the vacuum supply hose.
49 Undo the two retaining screws, disengage
the locating lug and remove the unit from its
mounting bracket.

Refitting

50 Refitting is a reversal of removal.

4A•8 Fuel and exhaust systems - single-point injection engines

12.47 Disconnect the ECU wiring

multiplug

12.35 Breather hose attachments at the

throttle body

12.30 . . . and lift off the stepper motor

12.28 Undo the four stepper motor

retaining screws (arrowed) . . .

12.18 Injector housing retaining screws

(arrowed)

1380 Rover 800 Series Remake

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Resonator unit

Removal

51 Apply the handbrake, jack up the front of
the car and support it on axle stands.
52 Undo the two screws and one bolt
securing the access panel to the underside of
the front wheelarch on the left-hand side.
53 Disengage the access panel from the front
spoiler, and remove it from under the car.
54 Undo the two bolts and withdraw the
resonator from under the front wheelarch.
55 Remove the spacers and rubber
mountings from the resonator.

Refitting

56 Refitting is a reversal of removal.

Inertia switch

Removal

57 From inside the car, remove the stud from
the centre console side cover on the left-hand
side, and remove the cover.
58 Undo the two screws securing the inertia
switch to the mounting plate, disconnect the
wiring multiplug and remove the switch.
59 Check the operation of the switch by
striking the forward-facing side hard against
the palm of your hand. The setting button
should trip out when this is done. If not, renew
the switch.

Refitting

60 Refitting is a reversal of removal. Press
the button down to reset the switch after
installation.

Manifold heater

Removal

61 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
62 Refer to Section 2 and remove the air
cleaner air box.
63 Relieve the fuel system pressure as
described in Section 5.
64 Release the clips and disconnect the two
fuel hoses at the injector housing.
65 Disconnect the manifold heater wiring
connector.
66 Undo the two bolts securing the fuel pipe
clips and the heater to the manifold, and
move the pipes aside.
67 Undo the remaining heater retaining bolt.
68 Open the throttle fully, and remove the
heater by pushing down with a long
screwdriver through the throttle aperture.
69 Remove the O-ring and gasket from the
heater.
70 Clean the mating faces of the heater and
manifold, and renew the gasket and O-ring if
they show any sign of deterioration.

Refitting

71 Refitting is a reversal of removal.

13 Exhaust system - general

information and component
renewal

Warning: Inspection and repair
of exhaust system components
should be done only after
enough time has elapsed after

driving the vehicle to allow the system
components to cool completely. Also,
when working under the vehicle, make
sure it is securely supported on axle
stands.

General information

1 The exhaust system consists of a front,
intermediate and rear section, suspended
from the underbody on rubber mountings, and
bolted to a cast iron manifold at the front. A
ball-and-socket universal joint is incorporated
in the front section, to allow for engine

and exhaust system movement (see
illustration).
2 The exhaust system should be examined
for leaks, damage and security at regular
intervals (see Chapter 1). To do this, apply the
handbrake, and allow the engine to idle in a
well-ventilated area. Lie down on each side of
the car in turn, and check the full length of the
system for leaks, while an assistant
temporarily places a wad of cloth over the end
of the tailpipe. If a leak is evident, stop the
engine and use a proprietary repair kit to seal
it. If the leak is excessive, or damage is
evident, renew the section. Check the rubber
mountings for deterioration, and renew them if
necessary.

Component renewal

Removal

3 To renew the system components, raise the
vehicle by means of axle stands or ramps to
provide adequate working clearance
underneath.

Fuel and exhaust systems - single-point injection engines 4A•9

13.1 Exhaust system components

1380 Rover 800 Series Remake

1 Front pipe
2 Flange gasket
3 Locknut
4 Intermediate

section

5 Flange gasket
6 Locknut
7 Rear section
8 Rubber

mountings

9 Mounting bracket

10 Rubber mounting
11 Tensioning spring

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1380 Rover 800 Series Remake

General

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indirect multi-point injection with microprocessor control

ECU-controlled idle speed:

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 to 950 rpm

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 to 900 rpm

Base idle speed:

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

725 to 775 rpm

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

675 to 725 rpm

Idle mixture CO content:

Non-catalyst equipped engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5 to 1.5%

Catalyst equipped engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.25%

Throttle potentiometer voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

315 to 335 mV

Fuel octane rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 RON leaded or 95 RON unleaded

Fuel Pump

Type:

Normally-aspirated engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nippon Denso, electric

Turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC electric

Output pressure:

Normally-aspirated engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 bar

Turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 bar

Regulated pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.0 to 2.3 bar

Delivery rate (at 3.0 bars and 12 volts):

Normally-aspirated engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 litres/hour

Turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 litres/hour

Turbocharger

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

Garret T25

Wastegate opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.34 to 0.36 bar

Chapter 4 Part B: Fuel and exhaust systems –
Lucas multi-point injection engines

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

Accelerator cable and linkage check and lubrication . . .See Chapter 1
Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . .

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

Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Catalytic converter - general information and

precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 4E

Exhaust manifold - removal and refitting . . . . . . . . . . .See Chapter 2A
Exhaust system - general information and component renewal . . . . 16
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . .

Fuel injection system - general information . . . . . . . . . . . . . . . . . . . 10
Fuel injection system - testing and adjustment . . . . . . . . . . . . . . . . 11

Fuel injection system components - removal and refitting . . . . . . . . 12
Fuel pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . .

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

Inlet manifold - removal and refitting  . . . . . . . . . . . . . .See Chapter 2A
Oxygen sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 4E
Turbocharger - description and precautions  . . . . . . . . . . . . . . . . . . 13
Turbocharger - examination and renovation  . . . . . . . . . . . . . . . . . . . 15
Turbocharger - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 14
Underbody fuel/brake line check . . . . . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
Unleaded petrol - general information and usage . . . . . . . . . . . . . . .

4B•1

Specifications

Contents

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

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General information and
precautions

The fuel system used on earlier Rover 820i,

Si, SLi and Turbo models consists of a
centrally-mounted fuel tank, electric fuel
pump and indirect multi-point fuel injection
(MPi) system, together with its related
electrical and mechanical components. A
more detailed description of the MPi system is
contained in Section 10.

The exhaust system consists of a front,

Precautions

Warning: Many of the
procedures in this Chapter
require the removal of fuel lines
and connections, which may

result in some fuel spillage. Petrol is
extremely flammable, so take extra
precautions when you work on any part of
the fuel system. Don’t smoke, or allow
open flames or bare light bulbs, near the
work area. Don’t work in a garage where a
natural gas-type appliance (such as a
water heater or clothes dryer) with a pilot
light is present. If you spill any fuel on your
skin, rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand. Before carrying out any operation
on the fuel system, refer also 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.

Reference must also be made to Chapter 5,

Certain adjustment points in the fuel system

are protected by tamperproof caps, plugs or

seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty.

When working on fuel system components,

scrupulous cleanliness must be observed and
care must be taken not to introduce any
foreign matter into the fuel lines or
components.

Air cleaner assembly -
removal and refitting

Note:

Air cleaner element renewal is

described in Chapter 1.

Removal

Normally-aspirated engines

1 Slacken the hose clip and disconnect the
air trunking at the throttle housing (see
illustration).
2 Disconnect the airflow meter wiring
connector, and release the cable from the
support clip.
3 Undo the two air cleaner body and airflow
meter support bracket bolts, and the two
bolts securing the forward air trunking to its
support bracket (see illustration).
4 Withdraw the air cleaner body, complete
with airflow meter and forward air trunking,

release the trunking from the connecting duct
at the front of the car, and remove the
assembly from the engine compartment.
5 If the cold air side intake is to be removed,
refer to Chapter 5 and remove the battery.
6 Undo the bolt securing the side intake to
the body, and remove the intake and duct.

Turbocharged engines

7 Remove the battery as described in
Chapter 5, then undo the bolts and lift out the
battery tray.
8 Undo the wastegate control solenoid valve
retaining screw and move the valve aside.
9 Disconnect the airflow meter wiring
multiplug.
10 Undo the three mounting bracket
retaining bolts.
11 Release the two clips securing the heat
shield to the heater pipe and remove the heat
shield.
12 Slacken the clip securing the air intake
hose to the turbocharger and release the
hose. Remove the breather hose from the
intake hose.
13 Disconnect the wiring multiplug from the
wastegate control solenoid valve.
14 Release the air cleaner assembly from the
intake duct and carefully lift out the air
cleaner, airflow meter and mounting bracket.
15 The remaining intake ducts can now be
removed as required.

Refitting

16 Refitting is a reversal of removal, but
ensure that all the ducts and trunking are fully
engaged before tightening the various
retaining bolts.

Torque wrench settings

lbf ft

Fuel filter banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake servo hose banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank strap locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust front pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust section flange nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust heat shield retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B•2 Fuel and exhaust systems - Lucas multi-point injection engines

2.3 Forward air trunking to support

bracket bolt

2.1 Disconnect the air trunking at the

throttle housing

1380 Rover 800 Series Remake

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Rover 820, 825, 827. Repair Manual - part 7