Rover 820, 825, 827. Repair Manual

Accelerator cable - removal,
refitting and adjustment

Removal

1 Open the throttle fully by hand, and slip the
inner cable end out of the slot on the throttle
lever (see illustration).
2 Slacken the outer cable locknuts, and fully
unscrew the outer locknut, nearest to the
cable end.
3 Remove the washer and rubber bush, then
withdraw the cable from the support bracket.
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

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 engine base idle speed as described in
Section 11.

Accelerator pedal -
removal and refitting

Refer to Part A, Section 4.

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 fuel pressure regulator, the fuel
injectors, 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 bleed
screw in the centre of the fuel filter outlet
union banjo bolt, then slowly unscrew the
bleed screw to relieve the system pressure.
5 Once the pressure has been completely
relieved, tighten the bleed screw and dispose
of the rags safely.

Fuel pump -
removal and refitting

Refer to Part A, Section 6.

Fuel gauge sender unit -
removal and refitting

Refer to Part A, Section 7.

Fuel tank - removal,
inspection and refitting

Refer to Part A, Section 8.

Unleaded petrol - general
information and usage

Refer to Part A, Section 9.

10 Fuel injection system -

general information

The multi-point fuel injection (MPi) system

is a microprocessor-controlled fuel
management system, designed to overcome
the limitations associated with conventional
carburettor induction. 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 then injected
directly into the inlet manifold, for all actual
and anticipated driving conditions.

The main components of the system and

their individual operation are as follows (see
illustration).

Fuel and exhaust systems - Lucas multi-point injection engines 4B•3

3.1 Accelerator cable end fitting

attachment at the throttle lever (A), and

outer cable locknuts (B)

1380 Rover 800 Series Remake

10.2 Main components of the multi-point fuel injection system

1 Flywheel reluctor

ring

2 Crankshaft sensor
3 Inertia switch
4 Fuel pump relay
5 Fuel ECU
6 Fuel pump
7 Fuel system main

relay

8 Fuel pressure

regulator

9 Fuel injector

10 Fuel rail
11 Fuel temperature

switch

12 Idle speed stepper

motor

13 Throttle housing
14 Throttle

potentiometer

15 Airflow meter
16 Speedometer

transducer

17 Coolant temperature

sensor

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

Fuel ECU:

The fuel ECU is a

microprocessor, which controls the entire
operation of the fuel system. Contained in the
ECU memory is a program which controls the
fuel supply to the injectors, and their opening
duration. The program enters sub-routines to
alter these parameters, according to inputs
from the other components of the system. In
addition to this, the engine idle speed is also
controlled by the ECU, which uses a stepper
motor to open or close an air valve as required.

Fuel injectors: Each fuel injector consists

of a solenoid-operated needle valve, which
opens under commands from the fuel ECU.
Fuel from the fuel rail is then delivered through
the injector nozzle into the inlet manifold.

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 sensor resistance.

Airflow meter: This contains two resistive

elements mounted in the intake air stream,
one of which is heated by a current passing
through it. Air passing over the heated wire
alters its resistance by cooling it, while the
temperature of the air is sensed by the other
wire. An electronic module within the airflow
meter monitors the reaction of the elements to
the airflow, and provides a proportional signal
to the ECU.

Throttle potentiometer: The potentiometer

is a variable resistor, attached to the throttle
shaft in the throttle housing. 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 fuel
ECU to determine throttle valve position, and
rate of change.

Idle speed stepper motor: This is a small

electric motor, having two control windings to
enable it to rotate in either direction. Under a
signal from the fuel ECU, the stepper motor
will rotate in whichever direction is necessary,
to open or close the air valve in the throttle
housing. This allows air to bypass the throttle
valve and maintain a stabilised idling speed.

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 an in-
line filter, to the fuel rail and fuel pressure
regulator.

Fuel pressure regulator: The regulator is a

vacuum-operated mechanical device, which
ensures that the pressure differential between
fuel in the fuel rail and fuel in the inlet manifold
is maintained at a constant value. As manifold
depression increases, the regulated fuel
pressure is reduced in direct proportion.
When fuel pressure in the fuel rail exceeds the
regulator setting, the regulator opens to allow
fuel to return via the return line to the tank.

Relays: The main relay is energised when

the ignition is switched on, and provides the
fuel ECU supply voltage. The fuel relay is

energised by the fuel ECU for a short period
after the ignition is initially switched on, and
then continuously when the engine is running.

Fuel temperature switch:

The fuel

temperature switch contacts remain open
during normal engine operation, and only
closes when the temperature of the fuel in the
fuel rail exceeds a preset value. When the
contacts close, a signal is sent to the fuel
ECU, overriding the coolant thermistor signal.
The ECU then alters the opening duration of
the injectors accordingly, to minimise the
effects of fuel vaporisation.

Inertia switch:

The switch is a

mechanically-controlled accelerator,
connected in the electrical circuit between the
ignition switch and the fuel ECU and fuel
relay. Under violent deceleration or impact,
the switch trips out, and cuts off the supply
voltage. Depressing a button on the switch
body resets the switch.

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 Check that there is at least 5.0 mm of free
play in the accelerator cable, and that the
throttle lever rests against its stop in the
released condition. Adjust the cable as
described in Section 3 if necessary.
5 Temperature effects, and engine and
transmission oil drag, can adversely influence

the idle speed and mixture settings, and it is
important that the following warm-up procedure
is adopted before attempting any adjustments.
6 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.
7 Return the car to the working area, and
without switching off the engine, connect an
exhaust gas analyser (CO meter) in accordance
with the equipment manufacturer’s
instructions. The analyser should be warmed
up, correctly calibrated and ready for
immediate use. Commence the adjustment
procedure described below immediately.
8 If, during the adjustment procedure, the
cooling fan operates, or if adjustment is not
completed within two minutes, accelerate the
engine to 2000 rpm, and hold this speed for
ten seconds. Repeat this every two minutes
until the adjustments are completed.

Base idle speed and mixture
adjustment

Note: On models equipped with a catalytic
converter, all adjustments should be entrusted to
a Rover dealer. Any maladjustment of the system
settings could have an adverse effect on the
operation of the emission control equipment.
9 The fuel injection system is such that the
engine idle speed and mixture settings are
controlled by the fuel ECU. Unless a new
component has been fitted, the idle speed or
mixture screws have been tampered with, or
the idle quality is unsatisfactory, no
adjustment should be necessary. If, however,
the settings are to be altered, an accurate
exhaust gas analyser (CO meter), tachometer,
and voltmeter will be required.
10 Refer to the engine tuning procedure
information contained above before starting.
11 Switch off all electrical accessories, and
ensure that they remain switched off
throughout the adjustment procedure.
12 With the engine idling and the exhaust gas
analyser connected, take a reading of the
exhaust gas CO content. If this is not as given
in the Specifications, hook out the tamperproof
plug over the idle mixture adjustment screw,
and turn the screw clockwise to enrich the
mixture, or anti-clockwise to weaken it as
necessary (see illustration).

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

11.12 Idle mixture adjustment screw

tamperproof plug (arrowed)

1380 Rover 800 Series Remake

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

13 With the CO content correctly adjusted,
switch off the engine and connect a
tachometer according to the manufacturer’s
instructions.
14 Before adjusting the base idle speed, the
stepper motor must be cycled to its fully-
extended position, using the following
procedure:
(a) Switch on the ignition.
(b) Disconnect the stepper motor wiring

multiplug on the top of the throttle
housing (see illustration).

(c) Switch off the ignition, wait five seconds,

and reconnect the stepper motor
multiplug.

(d) Switch on the ignition, wait five seconds,

and disconnect the stepper motor
multiplug again.

(e) Switch off the ignition, wait five seconds,

and reconnect the stepper motor
multiplug.

(f)

Switch on the ignition, wait five seconds,
and disconnect the stepper motor
multiplug once more. The stepper motor
is now fully extended.

15 Start the engine, and allow it to idle until
normal operating temperature is again
reached.
16 Check the reading on the tachometer, and
compare this with the base idle speed figure
given in the Specifications.
17 If adjustment is necessary, hook out the
tamperproof plug over the idle speed
adjusting screw, and turn the adjusting screw
as necessary to achieve the correct setting
(see illustration).
18 Increase the engine speed to 2000 rpm
for ten seconds, then return it to idle.
19 Recheck the exhaust CO content, as
described earlier in this Section.
20 Switch off the ignition, and pull back the
dust cover over the throttle potentiometer
wiring multiplug.
21 Insert the probes from the voltmeter into
the back of the multiplug so that the voltmeter
black lead is connected to the pink/black
wire, and the red lead is connected to the light
green/pink wire.
22 Select millivolts on the voltmeter, then
switch on the ignition.
23 Check that the reading on the voltmeter

scale is now equal to the throttle potentiometer
voltage, as given in the Specifications. If this is
not the case, slacken the two retaining screws,
and slowly move the potentiometer body until
the correct reading is obtained (see
illustration). Tighten the screws securely.
24 Open and close the throttle several times,
then with it closed, check the voltmeter
reading once more. Repeat the adjustment if
the reading is now outside the specified
tolerance.
25 With the adjustments complete, switch off
the engine and disconnect the test instruments.

12 Fuel injection system

components -
removal and refitting

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

Airflow meter - normally-
aspirated engines

Removal

1 Slacken the hose clip and detach the air
trunking from the airflow meter (see
illustration).
2 Release the airflow meter wiring harness

from its retaining clip, and disconnect the
wiring multiplug.
3 Undo the two bolts securing the unit to its
mounting bracket, withdraw the unit from the
air cleaner body, and recover the seal.

Refitting

4 Refitting is a reversal of removal.

Airflow meter - turbocharged
engines

Removal

5 Remove the air cleaner and airflow meter
assembly as described in Section 2.
6 Slacken the clip and disconnect the
turbocharger intake hose from the airflow
meter.
7 Undo the four bolts and three nuts and
separate the airflow meter from the air cleaner
and bracket assembly.

Refitting

8 Refitting is a reversal of removal.

Idle speed stepper motor

Removal

9 Slide back the rubber dust cover (where
fitted), and disconnect the stepper motor
wiring multiplug.

Fuel and exhaust systems - Lucas multi-point injection engines 4B•5

11.23 Throttle potentiometer retaining

screws (arrowed)

11.17 Base idle speed adjusting screw

tamperproof plug (arrowed)

11.14 Disconnect the stepper motor wiring

multiplug

12.1 Airflow meter attachments

1 Air trunking
2 Wiring harness retaining

clip

3 Wiring multiplug
4 Retaining bolts

5 Airflow meter
6 Seal location

1380 Rover 800 Series Remake

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

10 Using a 32 mm spanner, unscrew the
stepper motor from the throttle housing.

Refitting

11 Refitting is a reversal of removal.

Throttle potentiometer

Removal

12 Disconnect the throttle potentiometer
wiring harness multiplug.
13 Using a dab of paint, mark the position of
the potentiometer in relation to the throttle
housing, so that if the original unit is refitted,
its position can be restored.
14 Undo the two screws, remove the unit
from the throttle housing, and recover the
gasket (see illustration 11.23).

Refitting

15 Refit the potentiometer and gasket, align
the previously-made mark, then tighten the
two retaining screws. If a new unit is being
fitted, position it centrally within its
adjustment range.
16 Adjust the base idle speed and mixture
settings as described in Section 11.

Throttle housing

Removal

17 Drain the cooling system as described in
Chapter 1.

18 Slacken the hose clip and detach the air
intake trunking from the throttle housing (see
illustration).
19 Disconnect the throttle potentiometer and
stepper motor wiring multiplugs.
20 Disconnect the air valve hose from the top
of the housing, and the breather hose from
below.
21 Slacken the clips and disconnect the two
coolant hoses from the housing.
22 Open the throttle fully by hand, and slip
the accelerator inner cable end out of the slot
on the throttle lever.
23 Slacken the outer cable locknuts, and
unscrew the outer locknut, nearest to the
cable end, fully.
24 Remove the washer and rubber bush,
then withdraw the accelerator cable from the
support bracket.
25 On automatic transmission models,
disconnect the kickdown cable using the
same procedure as for the accelerator cable.
26 Undo the four retaining nuts and remove
the throttle housing from its mounting.
27 If further dismantling is required, the
stepper motor and throttle potentiometer can
be removed, as described earlier in this
Section.

Refitting

28 Refitting is a reversal of removal. Refill the
cooling system as described in Chapter 1
and, on automatic transmission models,

adjust the kickdown cable as described in
Chapter 7, Part B. Adjust the base idle speed
and mixture settings as described in Sec-
tion 11 on completion.

Fuel temperature switch

Removal

29 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
30 Disconnect the wiring multiplug from the
temperature switch, located in the centre of
the fuel rail behind the plenum chamber (see
illustration).
31 Unscrew the switch and remove it from
the fuel rail.

Refitting

32 Refitting is a reversal of removal.

Plenum chamber

Removal

33 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
34 Slacken the hose clip and detach
the air intake trunking from the throttle
housing.
35 Undo the four nuts securing the throttle
housing to the plenum
chamber, ease the housing off the studs, and
move it slightly to one side.
36 Disconnect the two vacuum hoses at the
throttle housing end of the plenum chamber
(see illustration).
37 At the other end of the plenum chamber,
unscrew the brake servo vacuum hose banjo
union bolt, disconnect the vacuum hose
adjacent to the banjo union, and undo the fuel
pressure regulator mounting bracket bolt (see
illustration). Recover the two copper washers
from the banjo union, and note that the hose
locates between two locating pegs in its fitted
position.
38 Remove the fuel temperature switch as
described previously.
39 Undo the two bolts securing the plenum
chamber mounting brackets to the camshaft
cover (see illustration).
40 Undo the six bolts securing the rear of the

4B•6 Fuel and exhaust systems - Lucas multi-point injection engines

12.39 Plenum chamber mounting bracket

to camshaft cover bolt (arrowed)

12.37 Brake servo vacuum hose banjo

union (A), additional vacuum hose (B), and

fuel pressure regulator mounting bracket

bolt (C)

12.36 Vacuum hose connections at the

throttle housing end of the plenum

chamber

12.30 Fuel temperature switch wiring

multiplug

12.18 Air intake trunking retaining clip (A),

air valve hose (B), and throttle housing

upper retaining nuts (C)

1380 Rover 800 Series Remake

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

plenum chamber to the inlet manifold (see
illustration).
41 Lift the plenum chamber off the manifold,
and recover the four locating sleeves and O-
ring seals.
42 Clean the manifold and plenum chamber
mating faces, and renew the O-ring seals if
they show any sign of deterioration.

Refitting

43 Refitting is a reversal of removal. Fit the
locating sleeves to the manifold before the O-
ring seals, and tighten all nuts and bolts
securely.

Fuel pressure regulator

Removal

44 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
45 Relieve the fuel system pressure as
described in Section 5.
46 Detach the breather hose from the
camshaft cover, and move the hose aside
(see illustration).
47 Disconnect the vacuum hose from the top
of the regulator (see illustration).
48 Unscrew the fuel return hose union from
the base of the regulator.
49 Undo the regulator bracket retaining
bolts, and withdraw the regulator from the fuel
rail.

Refitting

50 Refitting is a reversal of removal.

Fuel injectors

Removal

51 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
52 Relieve the fuel system pressure as
described in Section 5.
53 Remove the plenum chamber and fuel
temperature switch as described previously.
54 Detach the breather hose from the
camshaft cover, and move the hose aside.
55 Disconnect the fuel pressure regulator
vacuum hose.
56 Undo the fuel pressure regulator
mounting bracket bolts.
57 Undo the union nut, and disconnect the
fuel supply hose from the fuel rail.

58 Undo the union nut, and disconnect the
fuel return hose from the fuel pressure
regulator.
59 Disconnect the multiplugs from each of
the four injectors (see illustration).
60 Undo the two bolts securing the fuel rail to
the inlet manifold.
61 Ease the four injectors out of their inlet
manifold locations, and lift up the injector and
fuel rail assembly. Recover the O-ring seal
from each injector outlet.
62 Extract the retaining clips, and remove the
injectors from the fuel rail. Recover the O-ring
seal from each injector inlet.

Refitting

63 Refitting is a reversal of removal, but
renew the injector inlet and outlet O-rings.

Electronic control unit (ECU)

Removal

64 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
65 Slide the driver’s seat fully forwards.
66 From under the driver’s seat, undo the
two screws and lift off the ECU cover.

67 Undo the bolt securing the rear of the
mounting bracket to the floor (see
illustration).
68 Slide the driver’s seat fully rearwards, and
undo the two bolts securing the front of the
mounting bracket to the floor.
69 Withdraw the ECU and mounting bracket
assembly from under the seat.
70 Depress the multiplug retaining tab, and
pull the plug straight from the socket.
71 Remove the ECU from the car.

Refitting

72 Refitting is a reversal of removal.

Resonator unit

Refer to Part A, Section 12.

Inertia switch

Refer to Part A, Section 12.

13 Turbocharger - description

and precautions

Description

1 On turbocharged engines, the turbocharger
increases engine efficiency by raising the
pressure in the inlet manifold above
atmospheric pressure. Instead of the air
simply being sucked into the cylinders, it is
forced in.
2 Energy for the operation of the
turbocharger comes from the exhaust gas.

Fuel and exhaust systems - Lucas multi-point injection engines 4B•7

12.47 Fuel pressure regulator vacuum

hose (A) and mounting bracket bolts (B)

12.46 Detach the breather hose from the

camshaft cover

12.40 Plenum chamber to inlet manifold

retaining bolt locations

12.67 ECU mounting bracket retaining bolt

(arrowed)

12.59 Fuel injector and fuel rail details

1 Injector multiplug
2 Fuel rail retaining bolt
3 Fuel injector location on inlet manifold
4 Injector outlet O-ring seal
5 Injector to fuel rail retaining clip
6 Injector body
7 Injector inlet O-ring seal

1380 Rover 800 Series Remake

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

The gas flows through a specially-shaped
housing (the turbine housing) and in so doing,
spins the turbine wheel. The turbine wheel is
attached to a shaft, at the end of which is
another vaned wheel known as the
compressor wheel. The compressor wheel
spins in its own housing, and compresses the
inlet air on the way to the inlet manifold.
3 Boost pressure (the pressure in the inlet
manifold) is limited by a wastegate, which
diverts the exhaust gas away from the turbine
wheel in response to a pressure-sensitive
actuator.
4 The turbo shaft is pressure-lubricated by an
oil feed pipe from the main oil gallery. The
shaft “floats” on a cushion of oil. A drain pipe
returns the oil to the sump.

Precautions

5 The turbocharger operates at extremely
high speeds and temperatures. Certain
precautions must be observed, to avoid
premature failure of the turbo, or injury to the
operator.
6 Do not operate the turbo with any of its
parts exposed, or with any of its hoses
removed. Foreign objects falling onto the
rotating vanes could cause excessive
damage, and (if ejected) personal injury.
7 Do not race the engine immediately after
start-up, especially if it is cold. Give the oil a
few seconds to circulate.
8 Always allow the engine to return to idle
speed before switching it off - do not blip the
throttle and switch off, as this will leave the
turbo spinning without lubrication.
9 Allow the engine to idle for several minutes
before switching off after a high-speed run.
10 Observe the recommended intervals for
oil and filter changing, and use a reputable oil
of the specified quality. Neglect of oil
changing, or use of inferior oil, can cause
carbon formation on the turbo shaft, leading
to subsequent failure.

14 Turbocharger -

removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Drain the cooling system as described in
Chapter 1.
3 Remove the air cleaner complete with
airflow meter assembly as described in
Section 2.
4 Undo the bolts and remove the heat shield
behind the alternator.
5 Slacken the two clips and remove the oil
return hose at the base of the turbocharger.
6 Slacken the two hose clips and remove air
the outlet hose from the turbocharger.
7 Disconnect the vacuum hose at the
wastegate solenoid valve.
8 Disconnect the oil feed pipe unions at the
turbocharger.
9 Disconnect the coolant feed and return
hoses at the turbocharger and engine pipe
outlets.
10 Remove the engine oil dipstick and
release the dipstick tube from its upper
attachments.
11 Release the hose clips and support
brackets and remove the coolant pipe over
the top of the exhaust manifold.
12 Disconnect the wiring multiplug connector
above the alternator and release the cable
harness from its clips.
13 Disconnect the wastegate control
solenoid wiring.
14 Undo the three nuts and separate the
exhaust downpipe from the turbocharger
outlet flange.
15 Undo the exhaust manifold retaining nuts
and withdraw the manifold complete with

turbocharger assembly off the studs. Recover
the manifold gasket.
16 Undo the nuts securing the turbocharger
to the exhaust manifold and remove the
turbocharger. Recover the flange gasket .
17 Thoroughly clean all the joint mating faces
prior to refitting.

Refitting

18 Refitting is a reversal of removal, but use
new gaskets at all the flange joints. Refill the
cooling system and top-up the engine oil as
described in Chapter 1 on completion.

15 Turbocharger -

examination and renovation

1 With the turbocharger removed, inspect the
housing for cracks or other visible damage.
2 Spin the turbine or the compressor wheel,
to verify that the shaft is intact and to feel for
excessive shake or roughness. Some play is
normal, since in use, the shaft is “floating” on
a film of oil. Check that the wheel vanes are
undamaged.
3 If the exhaust or induction passages are oil-
contaminated, the turbo shaft oil seals have
probably failed.
4 No DIY repair of the turbo is possible. A
new unit may be available on an exchange
basis.

16 Exhaust system - general

information and component
renewal

Refer to Part A, Section 13 and, on vehicles

equipped with a catalytic converter, to Part E,
Section 3.

4B•8 Fuel and exhaust systems - Lucas multi-point injection engines

1380 Rover 800 Series Remake

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

1380 Rover 800 Series Remake

General

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

Modular Engine Management System (MEMS) with indirect multi-point
injection

ECU-controlled idle speed:

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

825 to 925 rpm

Pre-1994 turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

825 to 925 rpm

1994-on turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

775 to 875 rpm

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

95 RON unleaded only

Fuel Pump

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

AC electric

Output pressure:

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

3.2 bar

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

4.3 bar

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

2.8 to 3.2 bar

Delivery rate (at 3.0 bar and 12 volts):

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

64 litres/hour

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

73 litres/hour

Turbocharger

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

Garret T25

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

0.43 bar

Chapter 4 Part C: Fuel and exhaust systems –
MEMS 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 . . . . 17
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
Intercooler - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 . . . . . . . . . . . . . . .

4C•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

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

Torque wrench settings

lbf ft

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

Fuel pressure regulator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Plenum chamber to inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel rail to inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger exhaust elbow bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger to exhaust front pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

4C•2 Fuel and exhaust systems - MEMS multi-point injection engines

1380 Rover 800 Series Remake

General information and
precautions

The fuel system used on later Rover 820i,

Si, SLi and Vitesse models consists of a
centrally-mounted fuel tank, electric fuel
pump and indirect multi-point fuel injection,
as part of the Modular Engine Management
System (MEMS). A more detailed description
of the 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
catalytic converter is fitted between the front
and intermediate sections and a flexible joint is
also 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

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,

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.

Air cleaner assembly -
removal and refitting

Note:

Air cleaner element renewal is

described in Chapter 1.

Removal

Normally-aspirated engines

1 Remove the battery as described in
Chapter 5.
2 Slacken the hose clip and disconnect the
air intake hose between the throttle housing
and air cleaner at the air cleaner end.
3 Undo the two bolts securing the air cleaner
assembly to the mounting bracket.
4 Disengage the peg at the base of the air
cleaner, release the unit from the intake ducts
and remove it from the engine compartment.
5 The remaining intake ducts can now be
removed as required.

Turbocharged engines

6 Slacken the clip and release the air intake
hose on the side of the air cleaner body.
7 Slacken the clip and release the boost
control solenoid valve hose from its
connection next to the air intake hose.
8 Undo the two bolts on the side of the air

cleaner body and remove the unit from the
engine compartment.
9 The remaining intake ducts can now be
removed as required.

Refitting

10 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 Open the throttle fully by hand, and slip the
inner cable end out of the slot on the throttle
lever.
2 Unclip the square nut and release the cable
from the support bracket.
3 Release the cable from the support clip in
the engine compartment.
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 by turning the retainer
through 90º and withdraw the cable from the
car.

Refitting and adjustment

Models up to VIN 152206

7 Refit the cable at the pedal end using a
reversal of removal.
8 At the throttle housing end, screw the
square adjusting nut fully onto the threaded
portion of the outer cable.
9 Connect the inner cable to the throttle lever,
and locate the outer cable in the slot in the
support bracket.
10 Hold the throttle closed then pull the outer
cable away from the throttle lever until all
slack and lost motion are taken up.

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

11 Keeping the cable in this position, screw
the square nut along the threaded portion of
the outer cable until it just touches the
support bracket.
12 Without moving the square nut, clip it into
its slot in the support bracket.

Models from VIN 152206

13 Switch the ignition on, wait five seconds
then switch it off again. This will move the
stepper motor to the adjustment position.
14 Refit the cable at the pedal end using a
reversal of removal.
15 At the throttle housing end, screw the
square adjusting nut fully onto the threaded
portion of the outer cable.
16 Connect the inner cable to the throttle
lever, and locate the outer cable in the slot in
the support bracket.
17 Hold the throttle lever closed and check
that the throttle position screw is in contact
with the stepper motor pin.
18 Pull the outer cable away from the throttle
lever until all slack and lost motion are taken
up.
19 Keeping the cable in this position, screw
the square nut along the threaded portion of
the outer cable until it just touches the
support bracket.
20 Without moving the square nut, clip it into
its slot in the support bracket.

Accelerator pedal -
removal and refitting

Refer to Part A, Section 4, but note that the

accelerator pedal switch is only fitted to
certain models.

Fuel system -
depressurisation

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

Refer to Part B, Section 5.

Fuel pump -
removal and refitting

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

Refer to Part A, Section 6.

Fuel gauge sender unit -
removal and refitting

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

Refer to Part A, Section 7.

Fuel tank - removal,
inspection and refitting

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

Refer to Part A, Section 8.

Unleaded petrol - general
information and usage

Refer to Part A, Section 9.

10 Fuel injection system -

general information

The Modular Engine Management System

(MEMS) is used on later models equipped
with the “T” series 4-cylinder engine. It
controls a multi-point fuel injection system, an
emissions control system and a programmed
ignition system as a total engine management
package (see illustration).

One Electronic Control Unit (ECU) controls

all the fuelling, emission and ignition
requirements of the engine. The ECU
incorporates short circuit protection and can
also store information on certain intermittent
faults for interrogation by computerised test
equipment.

the ECU utilises a speed/density method of

airflow measurement to calculate fuel delivery.
This method, using the engine as a pre-
calibrated vacuum pump, with its
characteristics stored in the ECU, measures
the air inlet temperature and inlet manifold
pressure, allowing the correct amount of fuel
per air density/speed to be injected.

Should certain elements of the system fail,

the ECU can implement a back-up facility,
allowing the system to operate at a reduced
level of performance until the fault can be
rectified.

A diagnostic socket allows tuning or fault

diagnosis to be carried out on test equipment
without disconnecting the ECU wiring
harness.

On early versions of the system, an

accelerator pedal switch triggers the ECU
between the main fuelling map when the
switch is open (accelerator pedal depressed)
and idle speed control when the switch is
closed (pedal released). The pedal switch also

Fuel and exhaust systems - MEMS multi-point injection engines 4C•3

10.1 Main components of the MEMS multi-point fuel injection system

1380 Rover 800 Series Remake

1 Crankshaft sensor
2 Inertia switch
3 Fuel pump
4 Purge control valve
5 ECU
6 Relay module
7 Charcoal canister
8 Ignition coil
9 Diagnostic connector
10 Fuel pressure regulator
11 Fuel injectors
12 Fuel temperature sensor
13 Intake air temperature

sensor

14 Knock sensor
15 Throttle potentiometer
16 Stepper motor
17 Coolant temperature

sensor

18 Oxygen sensor
19 Distributor cap
20 Accelerator pedal switch
21 Purge control valve
22 Charcoal canister

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

controls an over-run fuel cut-off function. On
later versions of the system, the manifold
absolute pressure sensor is used to perform
the functions of the pedal switch.

The ECU, in determining optimum ignition

timing, receives information from the
crankshaft sensor (engine speed and
crankshaft position), manifold absolute
pressure sensor (engine load), knock sensor
(detonation), coolant temperature sensor
(engine temperature) and where fitted, from
the accelerator pedal switch (pedal position),
to determine main fuelling or idle speed
control.

It can be seen that the system is similar to

the earlier fuel injection system described in
Part B of this Chapter, the main differences
being the method of determining airflow (there
is no airflow meter) and the combining of the
fuel and ignition ECUs into one unit.

11 Fuel injection system -

testing and adjustment

Testing

system components individually, which is a
time-consuming operation that carries an
element of risk of damaging the ECU.

Adjustment

3 As all the fuelling and ignition requirements
are performed entirely by the electronic
control unit, no adjustments to the system are
possible. Any irregularities in idling speed
stability or engine performance may indicate a
fault in the system and should be referred to a
dealer for diagnosis and rectification.

12 Fuel injection system

components -
removal and refitting

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

Intake air temperature sensor

Removal

1 Disconnect the wiring multiplug from the
temperature sensor located on the inlet
manifold.
2 Unscrew the sensor and remove it from the
manifold.

Refitting

3 Refitting is a reversal of removal.

Throttle housing

Removal

4 Disconnect the wiring multiplugs from the
stepper motor and throttle potentiometer (see
illustration).
5 Slacken the clip and detach the air intake
hose from the throttle housing.
6 Disconnect the accelerator cable from the
throttle lever and support bracket as
described in Section 3.
7 On automatic transmission models,
disconnect the kick-down cable from the
throttle lever and support bracket referring to
Chapter 7, Part B if necessary.

8 Release the clips and disconnect the
breather hoses.
9 Unscrew the four nuts securing the throttle
housing to the inlet manifold and remove the
throttle housing.

Refitting

10 Refitting is a reversal of removal.
Reconnect and adjust the accelerator cable
as described in Section 3, and on automatic
transmission models, the kick-down cable as
described in Chapter 7, Part B.

Throttle potentiometer

Note: If the potentiometer is being renewed, it
will be necessary to have the new unit
adjusted by a Rover dealer on completion.

Removal

11 Remove the throttle housing as described
previously.
12 Using a dab of paint, mark the position of
the potentiometer in relation to the throttle
housing, so that if the original unit is refitted,
its position can be restored.
13 Undo the two screws, remove the unit
from the throttle housing, and recover the
gasket.

Refitting

14 Refit the potentiometer and gasket, align
the previously-made mark, then tighten the
two retaining screws.
15 If a new unit is being fitted, position it
centrally within its adjustment range.
16 Refit the throttle housing as described
previously.
17 Have the potentiometer adjusted by a
Rover dealer if a new unit was fitted.

Accelerator pedal switch

18 Refer to Part A, Section 4.

Fuel temperature sensor

Removal

19 Disconnect the wiring multiplug from the
temperature sensor located on the fuel rail.
20 Unscrew the sensor, remove it from the
fuel rail and recover the sealing washer.

Refitting

21 Refitting is a reversal of removal, but use a
new sealing washer.

Fuel pressure regulator

Removal

22 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
23 Relieve the fuel system pressure as
described in Part B, Section 5.
24 Disconnect the vacuum hose from the top
of the regulator (see illustration).
25 Release the clip and disconnect the fuel
return hose from the base of the regulator.
26 Undo the regulator bracket retaining
bolts, withdraw the regulator from the fuel rail
and recover the O-ring seal. Plug the fuel rail
while the regulator is removed.

4C•4 Fuel and exhaust systems - MEMS multi-point injection engines

12.4 Stepper motor and throttle potentiometer details

1 Intake hose clip
2 Intake hose
3 Stepper motor multiplug

4 Potentiometer multiplug
5 Breather hose
6 Throttle cable bracket

7 Cam lever
8 Kick-down cable cam lever
9 Throttle housing nuts

1380 Rover 800 Series Remake

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

Refitting

27 Refitting is a reversal of removal, but use a
new O-ring seal.

Plenum chamber

Removal

28 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
29 Slacken the hose clip and detach the air
intake trunking from the throttle housing.
30 Undo the four nuts securing the throttle
housing to the plenum chamber, ease the
housing off the studs, and move it slightly to
one side.
31 Disconnect the vacuum hoses at each
end of the plenum chamber.

32 Disconnect the purge control valve hose
from the plenum chamber (see illustration).
33 Unscrew the brake servo vacuum hose
banjo union bolt and recover the two copper
washers from the banjo union.
34 Detach the engine breather hose from the
plenum chamber.
35 Disconnect the fuel temperature sensor
wiring multiplug.
38 Undo the two bolts securing the plenum
chamber mounting brackets to the camshaft
cover.
39 Undo the six bolts securing the rear of the
plenum chamber to the inlet manifold.
40 Lift the plenum chamber off the manifold,
and recover the gasket.
41 Clean the manifold and plenum chamber
mating faces and obtain a new gasket.

Refitting

42 Refitting is a reversal of removal. Use a
new gasket and tighten the nuts and bolts to
the specified torque.

Fuel injectors and fuel rail

Removal

43 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
44 Relieve the fuel system pressure as
described in Part B, Section 5.
45 Remove the plenum chamber as
described previously.
46 Undo the four bolts and disconnect the
fuel feed hose flange bracket from the side of
the fuel rail. Plug the hose and fuel rail after
disconnection.
47 Disconnect the multiplugs from each of
the four injectors and move the injector wiring
harness aside.
48 Disconnect the vacuum hose from the top
of the fuel pressure regulator.
49 Release the clip and disconnect the fuel
return hose from the base of the regulator.

50 Undo the regulator bracket retaining
bolts, withdraw the regulator from the fuel rail
and recover the O-ring seal. Plug the fuel rail
while the regulator is removed.
51 Undo the three bolts securing the fuel rail
to the inlet manifold.
52 Ease the four injectors out of their inlet
manifold locations, and lift up the injector and
fuel rail assembly. Recover the O-ring seal
from each injector outlet.
53 Extract the retaining clips, and remove the
injectors from the fuel rail. Recover the O-ring
seal from each injector inlet.

Refitting

54 Refitting is a reversal of removal, but
renew the injector inlet and outlet O-rings.

Electronic control unit and relay
module

Removal

55 Lift the charcoal canister out of its
mounting bracket and move it to one side.
56 Release the relay module from the bracket
on the front of the ECU.
57 Disconnect the two wiring multiplugs and
the vacuum hose, then undo the three bolts
and remove the ECU from the mounting
bracket.

Refitting

58 Refitting is a reversal of removal.

Inertia switch

Removal

59 Disconnect the wiring multiplug, undo the
two screws and remove the switch from the
engine compartment bulkhead.

Refitting

60 Refitting is a reversal of removal.

Boost control solenoid
(Turbocharged engines)

Removal

61 Refer to Chapter 5, and remove the
battery.
62 Slacken the clip and release the air intake
hose on the side of the air cleaner body.
63 Slacken the clip and release the boost
control solenoid valve hose from its
connection next to the air intake hose on the
air cleaner.
64 Undo the two bolts on the side of the air
cleaner body and remove the unit from the
engine compartment.
65 Release the clips and disconnect the
three hoses from the boost control solenoid.
66 Disconnect the wiring multiplug, undo the
retaining bolt and remove the solenoid from
the battery tray.

Refitting

67 Refitting is a reversal of removal.

Camshaft sensor (Turbocharged
engines)

Removal

68 Disconnect the sensor wiring harness at
the connector.

Fuel and exhaust systems - MEMS multi-point injection engines 4C•5

12.24 Fuel pressure regulator attachments

2 Vacuum hose
3 Fuel return hose clip
4 Fuel return hose
5 Regulator bracket retaining bolts
6 Regulator bracket
7 Fuel pressure regulator

12.32 Plenum chamber attachment details

1380 Rover 800 Series Remake

3 Brake servo banjo bolt
4 Brake servo vacuum

pipe

5 Fuel temperature sensor

multiplug

6 Vacuum hoses
7 Purge control valve hose
8 Breather hose

10 Mounting bracket bolts
11 Mounting brackets
12 Plenum chamber to inlet

manifold bolts

13 Plenum chamber

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

69 Undo the retaining bolt and remove the
sensor from the housing on the end of the
cylinder head.

Refitting

70 Refitting is a reversal of removal.

13 Turbocharger - description

and precautions

Refer to Part B, Section 13.

14 Turbocharger -

removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Drain the cooling system as described in
Chapter 1.
3 Remove the air cleaner assembly as
described in Section 2.
4 Undo the two nuts and remove the
oil return hose elbow from the side of the
sump.
5 Undo the three nuts and separate the
exhaust downpipe from the turbocharger
outlet flange. Recover the flange gasket.
6 Undo the two bolts securing the coolant

pipe over the top of the exhaust manifold.
7 Release the oxygen sensor multiplug from
the thermostat housing, disconnect the
multiplug and remove the harness from the
clip on the top hose.
8 Slacken the hose clip and remove the
coolant pipe from the hose on the side of the
thermostat housing.
9 Slacken the hose clip and remove the air
intake hose from the turbocharger.
10 Slacken the two hose clips and remove air
the outlet hose from the turbocharger and
intercooler.
11 Disconnect the oil feed pipe union at the
turbocharger.
12 Disconnect the vacuum hose at the
wastegate solenoid valve.
13 Disconnect the coolant feed and return
hoses at the turbocharger.
14 Release the clip on the turbocharger
vacuum hose and remove the hose from the
turbocharger.
15 On models without air conditioning, undo
the nuts and remove the alternator heat
shield.
16 Undo the exhaust manifold retaining nuts
and bolts and withdraw the manifold
complete with turbocharger assembly off the
studs. Recover the manifold gasket.
17 Undo the nuts securing the turbocharger
to the exhaust manifold and remove the
turbocharger. Recover the flange gasket .
18 Thoroughly clean all the joint mating faces
prior to refitting.

Refitting

19 Refitting is a reversal of removal bearing
in mind the following points:
(a) Use new gaskets at all the flange joints

and new nuts at the turbocharger to
manifold connection.

(b) Tighten all nuts and bolts to the specified

torque.

(c) Refill the cooling system and top up the

engine oil as described in Chapter 1.

15 Turbocharger -

examination and renovation

Refer to Part B, Section 15.

16 Intercooler -

removal and refitting

The intercooler is removed as an assembly

with the cooling system radiator. Refer to
Chapter 3, Section 7 for details.

17 Exhaust system - general

information and component
renewal

Refer to Part A, Section 13 for exhaust

system details and to Part E, Section 3, for
information on the catalytic converter.

4C•6 Fuel and exhaust systems - MEMS multi-point injection engines

1380 Rover 800 Series Remake

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

1380 Rover 800 Series Remake

General

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

Programmed fuel injection system with sequential injection

Idle speed:

2.5 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

720 to 820 rpm

2.7 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

670 to 770 rpm

Idle mixture CO content

Models without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.25 to 0.75%

Models with catalytic converter * . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1%

* Non-adjustable - controlled by ECU
Fuel octane rating **:

Models without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 RON leaded or 95 RON unleaded

Models with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded only

** See text - Section 9

Fuel Pump

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

Nippon Denso, electric

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

4.1 bar

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

2.0 bar

Delivery rate (at 12 volts in 10 seconds) . . . . . . . . . . . . . . . . . . . . . . . . .

230 cc

Torque wrench settings

lbf ft

Electronic idle control valve retaining bolts . . . . . . . . . . . . . . . . . . . . . .

Fast idle valve retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Fuel rail banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle body retaining nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Exhaust front pipes to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Chapter 4 Part D: Fuel and exhaust systems –
Honda PGM-Fi 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 and intake components - removal and

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Cruise control system - general information  . . . . . . . . . . . . . . . . . . . 13
Cruise control system components - removal and refitting  . . . . . . . 14
Exhaust manifold - removal and refitting  . . . . . . . . . . .See Chapter 2A
Exhaust system - general information and component renewal . . . . 15
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
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 . . . . . . . . . . . . . . .

4D•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 V6 engine Rover

models consists of a centrally-mounted fuel
tank, electric fuel pump and Honda PGM-Fi
programmed fuel injection system A more
detailed description of the 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 two cast iron manifolds at the front.
A catalytic converter is fitted between the
front and intermediate sections on later
models and a flexible joint is also 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

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

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 and
intake components -
removal and refitting

Note:

Air cleaner element renewal is

described in Chapter 1.
Note: Due to the limited space available,
access to the air intake trunking and air
cleaner assembly can be improved if the
battery is removed first. If this is to be done,
refer to Chapter 5, Section 1, for precautions
concerning battery disconnection.

Air intake trunking

Removal

1 Release the coil HT cable from the clip on

top of the upper intake trunking (see
illustration).
2 Undo the breather pipe support bracket
bolt and remove the breather pipe from the
side of the upper intake trunking (see
illustration).
3 Slacken the clip securing the upper
trunking to the throttle body and the clip
securing the lower intake trunking to the air
cleaner assembly.
4 Release the trunking from the throttle body
and air cleaner; slacken the centre clip,
securing the upper and lower trunking parts
together.
5 Separate the upper trunking from the lower
trunking and manipulate both parts out of the
engine compartment.

Refitting

6 Refitting is a reversal of removal.

Air cleaner assembly

Removal

7 Remove the air intake trunking as described
previously.
8 Release the clip securing the resonator
vacuum hose to the front of the air cleaner
assembly and undo the wiring harness
support clip bolt at the rear (see
illustrations).
9 Slacken the air duct retaining clip.
10 Undo the two bolts securing the air
cleaner assembly to the battery tray (see
illustrations).

4D•2 Fuel and exhaust systems - Honda PGM-Fi injection engines

2.10a Undo the rear bolt arrowed . . .

2.8b . . . and undo the wiring harness

support clip bolt (arrowed) at the rear

2.8a Release the clip securing the

resonator vacuum hose to the front of the

air cleaner assembly . . .

2.2 Remove the breather pipe from the

side of the upper intake trunking

2.1 Release the coil HT cable from the clip

on top of the upper intake trunking

1380 Rover 800 Series Remake

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11 Release the air cleaner assembly from the
air duct, disengage the locating pegs and lift
the assembly out of the engine compartment.

Refitting

12 Refitting is a reversal of removal.

Air duct

Removal

13 Remove the battery as described in
Chapter 5.
14 Remove the air intake trunking and the air
cleaner assembly as described previously.
15 Undo the three bolts and lift out the
battery tray.
16 Undo the air duct upper retaining bolt,
release the duct from the resonator and
manipulate the assembly from its location.

Refitting

17 Refitting is a reversal of removal.

Accelerator cable - removal,
refitting and adjustment

Removal

1 Open the throttle fully by hand, and slip the
inner cable end out of the slot on the throttle
lever (see illustration).
2 Slacken the outer cable locknuts, then
withdraw the outer cable from the support
bracket (see illustration).

3 From inside the car, release the turnbuckles
and lift out the trim panel over the clutch,
brake and accelerator pedals.
4 Prise the retaining clip from the top of the
accelerator pedal, and disconnect the inner
cable.
5 Release the cable from the engine
compartment bulkhead, and the support clips;
withdraw the cable from the car (see
illustration).

Refitting and adjustment

6 Refitting is a reversal of removal. Adjust the
cable by means of the outer cable locknuts, to
give a small amount of free play with the
throttle closed. The adjustment is correct
when there is approximately 10 to 12 mm of
deflection on the inner cable.
7 Check that the throttle butterfly opens fully
with the accelerator pedal depressed to
the floor, and closes completely when
released.

Accelerator pedal -
removal and refitting

Refer to Part A, Section 4, but note that the

accelerator pedal switch is only fitted to
certain models. On models equipped with
cruise control, release the cruise control cable
from the pedal in the same way as the
accelerator cable.

Fuel system -
depressurisation

Note: 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 fuel pressure regulator, the fuel
injectors, 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 bleed
screw in the centre of fuel filter outlet union
banjo bolt, then slowly unscrew the bleed
screw to release the system pressure (see
illustration).
5 Once the pressure has been completely
relieved, tighten the bleed screw and dispose
of the rags safely.

Fuel pump -
removal and refitting

Refer to Part A, Section 6.

Fuel gauge sender unit -
removal and refitting

Refer to Part A, Section 7.

Fuel and exhaust systems - Honda PGM-Fi injection engines 4D•3

3.2 Slacken the outer cable locknuts, then

withdraw the outer cable from the support

bracket

3.1 Slip the accelerator inner cable end

out of the slot on the throttle lever

2.10b . . . and front bolt, securing the air

cleaner assembly to the battery tray

5.4 Releasing the fuel system pressure at

the bleed screw on the banjo union

3.5 Release the cable from the support

clips

1380 Rover 800 Series Remake

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Fuel tank - removal,
inspection and refitting

Refer to Part A, Section 8.

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,
consult one of the motoring organisations (or a
similar authority) for advice on the petrols
available and their suitability for your vehicle.
1 The recommended fuel is given in the
Specifications at the beginning of this
Chapter, followed by the equivalent petrol 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 V6 engine
models covered by this manual are designed
to run on leaded or unleaded petrols.
Depending on the petrol used, the ignition
timing will have to be adjusted accordingly.
Details of this procedure are covered in
Chapter 5, Section 10. Only unleaded petrol
may be used in those models fitted with a
catalytic converter.

10 Fuel injection system -

general information

The Honda PGM-Fi programmed fuel

injection system is used on all V6 engine
models covered by this manual. There are
detail differences between the system used
on the 2.5 litre engines and that used on
2.7 litre models, but these are of a minor
nature and mainly reflect the system’s
development over the years. The system is a
complex and highly sophisticated total engine
management package, controlling the fuel
injection, the fuel and exhaust emissions, and
the ignition system, from one electronic
control unit (ECU) (see illustration).

The tank-mounted fuel pump supplies fuel

under pressure to the fuel rails; the pressure
being controlled by the fuel pressure
regulator. Fuel from the fuel rails is supplied to
the fuel injectors which are then operated by
the ECU according to a number of operating
parameters.

The ECU contains memories for the basic

fuel injector opening times for various engine
speed and load conditions. Numerous
sensors on and around the engine are used to

4D•4 Fuel and exhaust systems - Honda PGM-Fi injection engines

10.1 Main components of the PGM-Fi programmed fuel injection system

Note: Components and locations may differ slightly between models

1 Ignition timing sensor
2 Manifold absolute pressure

sensor

3 Constant vacuum control

valve

4 Air suction control solenoid

valve

5 EGR control solenoid valve
6 Throttle dashpot air filter
7 Air reservoir
8 Pressure regulator control

cut-off solenoid valve

9 Bypass control solenoid

valve A

10 Bypass control solenoid

valve B

11 Main system ECU
12 Cooling fan timer module
13 Injector resistor pack
14 Air conditioning clutch

relay

15 Main system relay
16 Oil temperature sensor
17 Inertia switch
18 Transmission shift position

switch

19 Absolute pressure sensor
20 Crank/cylinder sensor
21 Fuel injectors

22 Fuel pump
23 Power steering switch
24 Oxygen sensor
25 EGR valve lift sensor
26 TDC sensor
27 Intake air temperature

sensor

28 Electronic idle control valve
29 Throttle angle sensor
30 Coolant temperature

sensor

31 Speedometer transducer
32 Resonator control valve

solenoid

33 ECU link connector

1380 Rover 800 Series Remake

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Rover 820, 825, 827. Repair Manual - part 8