Land Rover Rover 214 Repair 1689 04b Rover Manual

							1689 Rover 214 & 414 Updated Version 09/97
4B
Chapter 4 Part B  Fuel and exhaust systems -
single-point fuel injection engines
Accelerator cable - removal, refitting and adjustment  . . . . . . . . . . . 11
Accelerator pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 12
Air cleaner assembly - removal and refitting  . . . . . . . . . . . . . . . . . . . 3
Air cleaner air temperature control system - inspection and
component renewal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air cleaner filter element - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Exhaust manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 18
Exhaust system - inspection, removal and refitting  . . . . . . . . . . . . . 19
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . . 9
Fuel injection system components - removal and refitting  . . . . . . . . 15Fuel injection system components - testing  . . . . . . . . . . . . . . . . . . . 14
Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel system - inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel system - pressure check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold pre-heater - operation, removal and refitting  . . . . . . . 16
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 17
Throttle housing - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 13
4B•1
Contents
Specifications
System
Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rover/Motorola Modular Engine Management System, using ECU-
controlled single-point injection (MEMS-SPi) and speed/density
method of airflow measurement 
MEMS-SPi system data
Fuel pump type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric, immersed in fuel tank
Fuel pump pressure:
Maximum - at 16 volts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 bar
Regulated constant pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.2 bar
Injector/pressure regulator assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . JZX 3028
Throttle potentiometer voltage:
Throttle closed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 1 volt
Throttle open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 5 volts
Idle speed - nominal value given for reference purposes only  . . . . . . . . 850 ± 50 rpm
CO level at idle speed - engine at normal operating temperature:
Without catalytic converter - at tailpipe  . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 2.0 %
With catalytic converter - at gas-sampling pipe  . . . . . . . . . . . . . . . . . 0.5 to 2.0 %
Recommended fuel
Minimum octane rating:
Without catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON unleaded (ie: unleaded Premium) or 97 RON leaded 
(ie: 4-star)
With catalytic converter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON unleaded (ie: unleaded Premium)
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced  DIY
mechanicVery difficult,
suitable for expert DIY
or  professional
Degrees of difficulty
54321 
						

							Torque wrench settingsNm lbf ft
Fuel system
Injector housing fuel pipe union nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Injector housing fuel pipe adaptors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Injector housing screws  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4
Throttle housing retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13
Fuel system pressure release bolt - models without catalytic converter12 9
Fuel pump retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Vent valve and hose retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
ECU retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Intake air temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Coolant temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Inlet manifold nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Inlet manifold support stay bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Exhaust system
Oxygen (lambda) sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41
Exhaust manifold retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33
Exhaust manifold shroud screws  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4
Exhaust system flange nuts:
Manifold-to-front pipe joint  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
All other joints  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33
Exhaust front pipe mounting bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
4B•2 Fuel and exhaust systems - single-point fuel injection engines
1689 Rover 214 & 414 Updated Version 09/97
1 General information and
precautions
General information
The fuel system consists of a fuel tank
mounted under the rear of the vehicle with an
electric fuel pump immersed in it, a fuel filter,
fuel feed and return lines and the throttle body
assembly (which incorporates the single fuel
injector and the fuel pressure regulator), as
well as the Engine Management Electronic
Control Unit (ECU) and the various sensors,
electrical components and related wiring. The
ECU fully controls both the ignition system
and the fuel injection system, integrating the
two in a complete engine management
system (see illustration). Refer to Chapter 5
for information on the ignition side of the
system.
The Rover/Motorola Modular Engine
Management System uses ECU-controlled
single-point injection (MEMS-SPi) and the
speed/density method of airflow
measurement. The whole system is best
explained if considered as three sub-systems
which are, the fuel delivery, air metering and
electrical control systems.
The fuel delivery system incorporates the
fuel tank with an electric fuel pump, which is
immersed in a swirl pot to prevent aeration of
the fuel, inside it. When the ignition is
switched on, the pump is supplied with
current via the fuel pump relay, under the
control of the ECU. The pump feeds petrol via
a non-return valve (to prevent fuel draining out
of the system components and back to the
tank when the pump is not working) to the fuel
filter and from the filter to the injector. Fuel
pressure is controlled by the pressure
regulator, which lifts to allow excess fuel to
1.0  Fuel and ignition system components - MEMS-SPi
1 Accelerator pedal
switch
2 Fuel cut-out inertia
switch
3 Fuel pump
4 Throttle 
potentiometer
5 Fuel pressure
regulator
6 Injector
7 Stepper motor
8 Intake air temperature
sensor
9 Inlet manifold PTC
heater
10 Coolant 
temperature 
sensor
11 Distributor
12 Crankshaft sensor
13 Diagnostic connector
14 Engine management
ECU
15 Main relay
16 Fuel pump relay
17 Inlet manifold PTC
heater relay
18 Ignition HT coil
19 Lambda sensor -
models 
equipped with
catalytic 
converter
20 Lambda sensor relay -
models equipped with
catalytic converter
21 Purge valve (where
fitted)
22 Charcoal canister
(where fitted) 
						

							return to the tank swirl pot, where a venturi
causes the returning fuel to draw cool fuel
from the tank into the swirl pot. In the event of
sudden deceleration (ie: an accident) an
inertia switch cuts off the power to the pump
so that the risk of fire is minimised from fuel
spraying out of broken fuel lines under
pressure.
The air metering system includes the intake
air temperature control system and the air
cleaner, but the main components are in the
throttle body assembly. This incorporates the
injector, which sprays fuel onto the back of
the throttle disc, the throttle potentiometer,
which is linked to the throttle disc spindle and
sends the ECU information on the rate of
throttle opening by transmitting a varying
voltage, and the stepper motor, which is
controlled by the ECU and operates the
throttle disc spindle lever via a cam and
pushrod to provide idle speed control. Note
that there is no provision for adjustment of the
idle speed except by reprogramming the ECU
using Rover diagnostic equipment. If checking
idle speed, remember that it will vary
constantly under ECU control.
The electrical control system consists of the
ECU, with all the sensors that provide it with
information, and the actuators by which it
controls the whole system’s operation. The
ECU’s manifold absolute pressure sensor is
connected, by hoses and a fuel (vapour) trap
mounted in the air cleaner assembly, to the
inlet manifold. Variations in manifold pressure
are converted into graduated electrical signals
which are used by the ECU to determine the
load on the engine. The intake air temperature
sensor is self-explanatory, the crank-
shaft sensor gives it the engine speed and
crankshaft position, the coolant temperature
sensor gives it the engine temperature and the
accelerator pedal switch tells it when 
the accelerator is closed. The throttle
potentiometer is explained above and the
lambda sensor (where fitted) in Part D of this
Chapter. In addition, the ECU senses battery
voltage (adjusting the injector pulse width to
suit and using the stepper motor to increase
the idle speed and, therefore, the alternator
output if it is too low), incorporates short-
circuit protection and diagnostic capabilities
and can both receive and transmit informationvia the diagnostic connector, thus permitting
engine diagnosis and tuning by Rover
diagnostic equipment. If either the coolant
temperature sensor, the intake air
temperature sensor or the manifold absolute
pressure sensor circuits should fail to provide
adequate information, the ECU has a back-up
facility which assumes a value corresponding
to a coolant temperature of 60ºC, an intake air
temperature of 35ºC and an engine load
based on the engine speed and throttle
position. These are used to implement a
back-up air/fuel mixture ratio.
All these signals are compared by the ECU,
using digital techniques, with set values pre-
programmed (mapped) into its memory.
Based on this information, the ECU selects
the response appropriate to those values and
controls the ignition HT coil (varying the
ignition timing as required), the fuel injector
(varying its pulse width - the length of time the
injector is held open - to provide a richer or
weaker mixture, as appropriate), the stepper
motor (controlling the idle and fast idle
speeds), the fuel pump relay (controlling the
fuel delivery), the manifold heater relay
(controlling the inlet manifold pre-heater
system) and the main relay, the purge control
valve (where fitted) and the lambda sensor
and relay (where fitted) accordingly. The
mixture, idle speed and ignition timing are
constantly varied by the ECU to provide the
best settings for cranking, starting and engine
warm-up (with either a hot or cold engine),
idle, cruising and acceleration. A rev-limiter
circuit is built into the ECU which switches off
the injector earth (ie: the fuel supply) if engine
speed exceeds 6860 rpm, switching it back
on at 6820 rpm. The injector earth is also
switched off on the overrun (coolant
temperature above 80ºC, throttle pedal switch
contacts closed, engine speed above
1500 rpm) to improve fuel economy and
reduce exhaust emissions.
The ECU idle control is an adaptive system
which learns the engine load and wear
characteristics over a period of time and
adjusts the idle speed to suit. If the ECU is
renewed, or one from another vehicle is fitted,
it will take a short period of normal driving forthe new ECU to learn the engine’s
characteristics and restore full idle control.
To reduce emissions and to improve
driveability when the engine is cold, the inlet
manifold is heated by the cooling system
coolant and by an electric pre-heater system.
Mixture enrichment for cold starting is a pre-
programmed function of the system.
The air cleaner contains a disposable paper
filter element and incorporates a flap valve air
temperature control system which allows 
cold air from the outside of the vehicle and
warm air from the exhaust manifold to enter
the air cleaner in the correct proportions.
The exhaust system is as described in Part
A of this Chapter.
Precautions
Fuel injection system
Residual pressure will remain in the fuel
lines long after the vehicle was last used,
therefore extra care must be taken when
disconnecting a fuel line hose. Loosen any
fuel hose slowly to avoid a sudden release of
pressure which may cause fuel spray. As an
added precaution, place a rag over each
union as it is disconnected to catch any fuel
which is forcibly expelled.
Fuel usage
Refer to Part A of this Chapter. 
Catalytic converters
Before attempting work on these items,
carefully read the precautions listed in Part D
of this Chapter. 
2 Air cleaner filter element-
renewal
Refer to Chapter 1.
3 Air cleaner assembly-
removal and refitting
2
Removal
1Release the two clips securing the air intake
duct to the assembly, then undo the three
screws securing the assembly to the throttle
body (see illustration).
2Release the assembly from the intake duct
and withdraw it, collecting the throttle housing
seal and the intake duct sealing ring (where
fitted), then disconnect the following (see
illustration):
a) The thermac switch vacuum pipes. These
are colour-coded (yellow to the
temperature control valve, red to the inlet
manifold).
b) The ECU manifold absolute pressure
sensor fuel trap vacuum hoses. These are
colour-coded (green to the ECU, white to
the inlet manifold).
c) The intake air temperature sensor wiring.
Fuel and exhaust systems - single-point fuel injection engines  4B•3
3.2  Thermac switch vacuum pipes (A), fuel
trap vacuum hoses (B), intake air
temperature sensor wiring (C) and throttle
housing seal (D)
3.1  Releasing clips to separate intake duct
from air cleaner
4B
1689 Rover 214 & 414 Updated Version 09/97 
						

							3Check the condition of the throttle housing
seal and the intake duct O-ring (where fitted).
Renew either if worn or damaged.
4To remove the metal intake duct, refer to
Section 4, paragraphs 3 and 4.
5To remove the air intake hose it will first be
necessary to remove the left-hand headlamp
assembly, to gain access to the two retaining
screws. Remove the two retaining screws and
disconnect the duct from the body front
panel, release the clip securing the ignition HT
lead, then slacken the retaining clamp and
unfasten the rubber strap to separate the cold
air duct from the intake duct. Release the
intake hose from the resonator T-piece and
remove it from the engine compartment.
6A resonator chamber is fitted to the intake
hose to reduce the amount of induction noise.
To remove the chamber, first remove the
battery and battery tray. Disconnect the intake
hose from the T-piece then remove the
resonator T-piece. Release any relevant
retaining clips from the resonator, then
remove the resonator from the engine
compartment (see illustrations).
Refitting
7Refitting is the reverse of the removal
procedure. Ensure that the vacuum pipes and
hoses are correctly reconnected and are not
trapped as the assembly is refitted, then
check that the assembly sits properly on the
throttle body before tightening the screws
securely.
4 Air cleaner air temperature
control system- inspection
and component renewal
2
Inspection
1Refer to Section 4 in Part A of this Chapter.
Thermac switch - renewal
2Refer to Section 4 in Part A of this Chapter,
removing the air cleaner assembly as
described in the previous Section.
Air temperature control valve -
renewal
3Disconnect the vacuum pipe from the air
temperature control valve, then slacken the
intake hose retaining clamp. Release the
intake hose rubber retaining strap and
disconnect the hose from the metal intake
duct (see illustration).
4Release the two clips securing the air intake
duct to the air cleaner assembly and undo the
bolt securing the duct to its mounting bracket
(see illustration). Withdraw the duct, taking
care not to lose the hot air intake connector
hose which connects the duct to the exhaust
manifold shroud.
5The air temperature control valve can be
renewed only with the complete intake duct
assembly. If a new intake duct assembly is
being fitted, undo the three screws securingthe hot air intake adaptor plate to the bottom
of the duct and transfer the adaptor plate to
the new duct.
6Refitting is the reverse of the removal
procedure.
5 Fuel system- inspection
Refer to Chapter 1.
6 Fuel system-
depressurisation
2
Warning: The following
procedure will merely relieve the
pressure in the fuel system.
Remember that fuel will still be
present in the system components and
take precautions accordingly before
disconnecting any of them.
1The fuel system referred to in this Section is
defined as the tank-mounted fuel pump, the
fuel filter, the fuel injector and the pressure
regulator in the injector housing, and the
metal pipes and flexible hoses of the fuel lines
between these components. All these contain
fuel which will be under pressure while the
engine is running and/or while the ignition is
switched on. 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 work.
Models with a catalytic
converter
2On models equipped with a catalytic
converter, the system is depressurised via the
small bolt fitted to the fuel filter inlet (feed)
union nut.
3Position wads of rag around the union to
catch the spilled fuel and slowly slacken the
bolt.
4Once all pressure has been released,
remove the bolt. Inspect the sealing washer
for signs of wear or damage and renew if
necessary.
5Refit the bolt and sealing washer to the
union nut and tighten it securely.
Models without a catalytic
converter
6On models not fitted with a catalytic
converter, the system is depressurised via the
bolt in the metal fuel filter outlet pipe.
7Position wads of rag around the pipe to
catch the spilled fuel as the bolt is removed.
Carefully slacken the bolt whilst holding the
fuel pipe boss with an open-ended spanner to
4B•4 Fuel and exhaust systems - single-point fuel injection engines
4.4  Unfastening intake duct-to-support
bracket retaining bolt4.3  Unfastening cold air intake duct
rubber strap - vacuum pipe (A) and clamp
screw (B)
3.6b  . . . then remove resonator3.6a  Remove T-piece . . .
1689 Rover 214 & 414 Updated Version 09/97 
						

							prevent any undue strain being placed on the
fuel pipe (see illustration).
8Once all pressure has been relieved,
remove the bolt and inspect the sealing
washer for signs of wear or damage and
renew if necessary. 
9Refit the bolt and washer to the fuel pipe
and tighten it to the specified torque wrench
setting whilst using a spanner to counter-hold
the pipe boss, to prevent the pipe or filter
being damaged.
7 Fuel system- pressure check
1The following procedure is based on the
use of the Rover pressure gauge and adaptor
(Service tool numbers 18G 1500 and 
18G 1500/3).
2Depressurise the fuel system.
3Unscrew the pressure release bolt and
screw in the adaptor, then connect the
pressure gauge.
4Turn the engine over on the starter motor.
The pressure should reach the specifiedvalue. Stop cranking the engine and watch the
gauge. The pressure drop in the first minute
should not exceed 0.7 bar.
5If the pressure first recorded was too high,
renew the pressure regulator, which means
renewing the complete injector housing
assembly.
6If the pressure first recorded was too low or
if it falls too quickly, check the system
carefully for leaks. If no leaks are found, check
the pump by substituting a new one, then
recheck the pressure. If the pressure does not
improve, the fault is in the pressure regulator
and the complete injector housing assembly
must be renewed. If this is the case, it is worth
dismantling the regulator to check that the
fault is not due to its being jammed open with
dirt.
8 Fuel pump- 
removal and refitting
3
Removal
1Remove the fuel tank.
2Release the clips securing the tank vent
hose to the fuel tank breather and fuel cut-off
valve, then disconnect the hose. Undo the
vent hose and valve retaining nuts, then
disconnect the vent valve hose from the fuel
pump and remove the vent hose and valve
assembly from the tank (see illustration).
3Disconnect the wiring connector from the
fuel pump.
4Slacken and remove the six fuel pump
retaining nuts. Carefully withdraw the fuel
pump assembly from the tank and remove 
the pump seal.
Refitting
5Refitting is a reversal of the removal
sequence, noting the following:a) Renew the pump seal if there is any doubt
as to its condition.
b) Tighten all retaining nuts to the specified
torque setting.
c) Ensure that the vent hoses are correctly
connected and are securely held by any
necessary retaining clips.
9 Fuel gauge sender unit-
removal and refitting
Refer to Section 7 in Part A of this Chapter.
10 Fuel tank- 
removal and refitting
1Refer to Section 8 in Part A of this Chapter.
Note that the fuel system must be
depressurised before any fuel hose is
disconnected.
11 Accelerator cable- removal,
refitting and adjustment
2
Removal
1Remove the four windscreen wiper motor
mounting bolts to free the motor from the
engine compartment bulkhead.
2Slacken the accelerator cable locknuts and
free the cable outer from its mounting bracket.
Release the cable inner from the throttle cam
(see illustration).
3Work back along the cable outer and
release it from any retaining clamps.
4Working inside the vehicle, undo the five
right-hand lower facia panel retaining screws
and remove the panel.
5Release the cable from the upper end of the
accelerator pedal and withdraw the cable
from the engine compartment.
Refitting
6Refitting is the reverse of the removal
procedure. Tighten the windscreen wiper
motor retaining bolts to the specified torque
Fuel and exhaust systems - single-point fuel injection engines  4B•5
6.7  Slackening pressure release bolt to
depressurise fuel system - non-catalyst
system
11.2  Disconnecting accelerator cable from
throttle cam pulley8.2  Fuel pump connections
4B
1689 Rover 214 & 414 Updated Version 09/97 3 Tank vent hose
4 Vent pipe nuts
5 Vent valve nut
6 Cut-off valve hose
7 Pump multiplug
8 Pump housing nuts
9 Pump housing seal 
						

							(Chapter 12) and prior to tightening the cable
locknuts, adjust the cable as follows.
Adjustment
7With the pedal fully released, check that
there is equal clearance on each side of the
throttle lever at the lost motion link (see
illustration)and no slack in the cable. Have
an assistant fully depress the pedal and check
that the throttle cam opens fully, then check
that it returns to the at-rest position when
released.
8To adjust the cable, switch on the ignition
and position the stepper motor by moving the
cam only to open, and fully close the throttle.
Note that it is essential for accurate
positioning of the stepper motor that the
accelerator pedal switch contacts remain
closed, so that the ECU recognises the
throttle movement as a command and
indexes the stepper motor to 25 steps.
9Slacken the adjuster locknut (upper nut),
then tighten the adjuster (lower) nut until the
clearance is equal on each side of the throttlelever at the lost motion link. Tighten the
locknut without disturbing this setting.
Recheck the adjustment and switch off the
ignition.
12 Accelerator pedal- 
removal and refitting
Refer to Section 10 in Part A of this Chapter.
13 Throttle housing- 
removal and refitting
2
Removal
1Depressurise the fuel system.
2Disconnect the battery negative terminal
and remove the air cleaner assembly.
3Examine the injector housing fuel pipe feed
and return unions for signs of leakage, then
wipe them clean.
4Using a spanner to hold each adaptor,
unscrew the pipe union nuts and release the
fuel feed and return pipes from the adaptors.
Plug each pipe and adaptor to minimise the
loss of fuel and prevent the entry of dirt into
the system.
5Release the wire retaining clips then
disconnect the wiring connectors from the
injector housing, the throttle potentiometer
and the stepper motor.
6Slacken the accelerator cable locknuts and
free the cable outer from its mounting bracket.
Release the cable inner from the throttle cam.
7Using a suitable pair of pliers, release the
retaining clips and disconnect the breather
hoses from the throttle housing (see
illustration).
8Slacken and remove the four nuts securing
the throttle housing to the inlet manifold, then
remove the throttle housing from the vehicle.
Remove the throttle housing insulating spacer
and examine it for signs of wear or damage,
renewing it if necessary (see illustrations).
9If leakage was detected from the feed and
return pipes or their union nuts, check the
sealing surfaces of the nuts and adaptors andrenew the adaptor or the pipe assembly, as
necessary.
10If leakage is detected from the adaptors,
unscrew each through one turn with a
spanner, then through two turns by hand. If
the adaptor is still a tight fit in the housing, the
threads are damaged and the housing and
adaptors must be renewed as a set. If the
threads are sound, fit new sealing washers to
the adaptors and refit them, tightening them
to their specified torque wrench setting.
Refitting
11Refitting is a reverse of the removal
sequence, noting the following:
a) Ensure that the mating surfaces of the
throttle housing and inlet manifold are
clean then fit the insulating spacer.
b) Tighten the throttle housing and fuel pipe
union nuts to their specified torque
settings.
c) On completion, reconnect and adjust the
accelerator cable.
14 Fuel injection system
components- testing
5
1If a fault appears in the engine management
(ignition/fuel injection) system, first ensure
that the fault is not due to poor maintenance.
That is, check that the air cleaner filter
element is clean, the spark plugs are in good
condition and correctly gapped, and that the
engine breather hoses are clear and
undamaged. Also check that the throttle cable
is correctly adjusted. If the engine is running
very roughly, check its compression
pressures, bearing in mind that possibly one
of the hydraulic tappets might be faulty,
producing an incorrect valve clearance.
2If these checks fail to reveal the cause of
the problem, the vehicle should be taken to a
suitably-equipped Rover dealer for testing. A
wiring block connector is incorporated in the
engine management circuit into which a
special electronic diagnostic tester can be
plugged. The tester will locate the fault quickly
and simply, thereby alleviating the need to
test all the system components individually
4B•6 Fuel and exhaust systems - single-point fuel injection engines
13.8b  . . . and remove throttle body gasket
spacer13.8a  Lift throttle body assembly away
from inlet manifold . . .13.7  Disconnecting breather hoses from
throttle housing
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11.7  Accelerator cable adjustment
1 Throttle lever to lost motion link clearance
should be equal on each side
2 Adjuster nut
3 Adjuster locknut 
						

							which is a time consuming operation that
carries a high risk of damaging the ECU.
3If necessary, the system wiring and wiring
connectors can be checked as described in
Chapter 12. Ensure that the ECU wiring
connectors have first been disconnected.
15 Fuel injection system
components- removal and
refitting
3
Injector housing
Removal
1Carry out the operations described in
paragraphs 1 to 4 of Section 13 (see
illustration).
2Release the wire retaining clip and
disconnect the wiring connector from the
injector housing (see illustration).
3Remove the four screws securing the
injector housing to the throttle body, then lift
off the injector housing and remove the
gasket (see illustrations).
4If leakage was detected from the fuel feed
and/or return pipes, perform the checks
described in paragraph 9 of Section 13.
Refitting
5Refitting is a reversal of the removal
procedure, noting the following:a) Ensure the injector and throttle housing
mating surfaces are clean, then fit a new
gasket.
b) Apply thread locking compound (Rover
recommend Loctite Screwlock or Nutlock)
to the threads of the injector housing
screws, then tighten them to the specified
torque.
c) Tighten the fuel pipe union nuts to the
specified torque setting.
Fuel injector
Removal
6Note that as a Rover replacement part, the
injector is available only as part of the injector
housing. Commence removal by
depressurising the fuel system.
7Disconnect the battery negative terminal
then remove the air cleaner assembly.
8Slacken and remove the injector connector
cap retaining screw and lift off the connector
cap. The injector can then be lifted out of the
housing (see illustrations).
Refitting
9Refitting is the reverse of the removal
procedure. Ensure that the connector 
cap makes good contact with the injector
pins.
Fuel pressure regulator
10The fuel pressure regulator is availableonly as part of the injector housing assembly.
Refer to paragraphs 1 to 5 for details on
removal and refitting.
Stepper motor
Removal
11Remove the injector housing as described
in paragraphs 1 to 4.
12Release the retaining clip and disconnect
the stepper motor wiring connector (see
illustration).
13Remove the four stepper motor retaining
screws and remove the stepper motor
assembly from the throttle housing (see
Fuel and exhaust systems - single-point fuel injection engines  4B•7
15.3a  Injector housing-to-throttle body
screws (A), connector cap screw (B) and
pressure regulator screws (C)
15.3b  Remove injector housing from
throttle body - noting gasket
15.2  Disconnecting wiring connector from
injector housing15.1  Disconnecting fuel feed and return
pipes from injector housing
15.12  Disconnecting stepper motor wiring
connector15.8b  . . . and withdraw injector15.8a  Remove screw then lift off injector
connector cap . . .
4B
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							illustrations). Do not attempt to dismantle the
assembly.
Refitting
14Refitting is the reverse of the removal
procedure. Ensure that the throttle housing
and motor mating surfaces are clean and on
completion, adjust the throttle cable to ensure
that the stepper motor is correctly indexed.
Throttle potentiometer
Removal
15Although not strictly necessary, access is
greatly improved if the air cleaner assembly is
first removed.16Disconnect the battery negative lead.
17Release the wire retaining clip and
disconnect the potentiometer wiring
connector (see illustration).
18Remove the two screws and remove the
potentiometer from the throttle housing,
noting how its tongue engages with the
throttle disc spindle lever. Withdraw the
spacer if required.
Refitting
19Refitting is the reverse of the removal
procedure, noting the following (see
illustration):
a) Carefully clean the mating surfaces of the
throttle body, the spacer and the
potentiometer, then refit the spacer.
b) Refit the potentiometer so that its tongue
engages FORWARD of (ie: inside) the
throttle disc spindle lever, then rotate the
throttle cam to check the action of the
lever and tongue.
c) Securely tighten the potentiometer
screws then recheck the potentiometer
operation before reconnecting the wiring
connector.
Engine management
(ignition/fuel injection) ECU
Removal
20Disconnect the battery negative terminal
and unplug the wiring connector(s) from the
ECU (see illustration).21Disconnect the absolute pressure sensor
vacuum hose from the unit, then undo the
three retaining nuts and remove the ECU from
the engine compartment (see illustrations).
Refitting
22Refitting is a reverse of the removal
sequence. Tighten the ECU retaining nuts to
the specified torque. Due to the nature of the
ECU, if a new or different ECU has been fitted,
it may take a short while for full idle control to
be restored.
Manifold absolute pressure
sensor
23This is part of the ECU and is removed
and refitted as described above.
24The sensor’s vacuum hose runs from the
inlet manifold to the ECU via a fuel (vapour)
trap mounted in the air cleaner assembly.
25To remove the fuel trap, remove the air
cleaner assembly cover, release the clips and
disconnect the hoses, then remove the single
retaining screw and withdraw the trap.
26On refitting, note that the hoses are
colour-coded (green to the ECU, white to the
inlet manifold) to ensure correct reconnection
(see illustration).
Intake air temperature sensor
Removal
27Disconnect the battery negative lead.
4B•8 Fuel and exhaust systems - single-point fuel injection engines
15.21b  . . . then undo ECU mounting nuts
(arrowed) and remove unit15.21a  . . . and absolute pressure sensor
vacuum hose from ECU . . .15.20  Disconnect wiring connector . . .
15.19  Ensure potentiometer tongue
engages correctly with throttle lever
(spacer arrowed)
15.17  Disconnecting throttle
potentiometer wiring connector (mounting
screws arrowed)15.13b  . . . and remove stepper motor
assembly15.13a  Undo stepper motor retaining
screws (arrowed) . . .
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							28Remove the air cleaner metal intake duct
(see illustration).
29Release the wire clip and disconnect the
sensor wiring.
30Unscrew the sensor and remove it from
the air cleaner housing.
Refitting
31Refitting is the reverse of the removal
procedure. Tighten the sensor to its specified
torque wrench setting.
Coolant temperature sensor
Removal
32The coolant temperature sensor is fitted
to the underside of the inlet manifold (see
illustration). Either drain the cooling system
or be prepared for some loss of coolant as the
sensor is unscrewed.
33Release the wire retaining clip and
disconnect the wiring connector from the
sensor.
34Unscrew the sensor from the manifold
and withdraw it, then plug the opening to
prevent the entry of dirt. If the cooling system
has not been drained, work quickly to
minimise coolant loss.
Refitting
35Wipe clean the threads of the sensor and
of the thermostat housing. If a sealing washer
is fitted, renew it whenever it is disturbed toprevent leaks. If no sealing washer is fitted,
apply a smear of sealant to the sensor
threads.
36Refit the sensor, working quickly if the
cooling system was not drained, and tighten it
to the specified torque. Reconnect the wiring
connector.
37Replenish the cooling system.
Accelerator pedal switch
38Refer to Section 11 in Part A of this
Chapter.
Fuel cut-off inertia switch
39The fuel cut-off inertia switch is located
behind the centre console where it is mounted
on the steering column support bracket. If the
switch has tripped, it can be reset by pressing
in the plunger situated at the top of the switch
(see illustration).
Removal
40Remove the centre console.
41Disconnect the wiring connector, then
undo the switch mounting bracket retaining
nut and remove the switch (see illustrations).
Refitting
42Refitting is a reverse of the removal
sequence. Before installing the centre
console, reset the inertia switch by pressing in
the plunger.
Relays
43Refer to Chapter 12 for further
information.
16 Inlet manifold pre-heater-
operation, removal and
refitting
1Refer to Section 15 in Part A of this
Chapter. Note that there is no separate
manifold pre-heater temperature switch. The
ECU uses the information sent from the
coolant temperature sensor (see illustration).
Fuel and exhaust systems - single-point fuel injection engines  4B•9
15.32  Coolant temperature sensor
(arrowed)
15.39  Reset fuel cut-off inertia switch by
depressing plunger
15.28  Remove air cleaner metal intake
duct to gain access to intake air
temperature sensor15.26  Absolute pressure sensor fuel trap
hoses are colour-coded to ensure correct
refitting
16.1  Inlet manifold partially removed to
show manifold PTC heater and coolant
temperature sensor (arrowed)15.41b  . . . and remove switch15.41a  Undo inertia switch retaining 
nut . . .
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							17 Inlet manifold- 
removal and refitting
3
Removal
1Remove the throttle housing.
2Drain the cooling system.
3Slacken the retaining clamps and
disconnect the coolant hoses from the inlet
manifold (see illustration).
4Slacken and remove the brake vacuum
servo unit hose union bolt and disconnect the
hose (see illustration). Discard the hose
union sealing washers which must be
renewed whenever they are disturbed.
5Undo the single bolt securing each
manifold support stay to the cylinder
block/crankcase and slacken the bolts which
secure the stays to the inlet manifold.
6Make a final check that all the necessary
vacuum hoses have been disconnected from
the manifold then unscrew the nuts and bolts
securing the manifold to the cylinder head.Manoeuvre the manifold out of the engine
compartment and discard the manifold gasket
(see illustrations).
Refitting
7Refitting is the reverse of the removal
procedure, noting the following (see illustration):
a) Ensure that the manifold and cylinder
head mating surfaces are clean and dry,
then fit a new manifold gasket.b) Working in the sequence shown, tighten the
manifold retaining nuts and bolts evenly, to
the specified torque wrench setting.
c) Ensure all relevant hoses are reconnected to
their original positions and are securely held
(where necessary) by the retaining clips.
d) Renew the vacuum servo unit vacuum
hose banjo union sealing washers and
tighten the union bolt securely.
e) On completion, refill the cooling system.
4B•10 Fuel and exhaust systems - single-point fuel injection engines
17.7  Inlet manifold tightening sequence - K16 engine
17.6b  Remove inlet manifold and withdraw gasket17.6a  Ensure all vacuum pipes and hoses are disconnected
17.4  . . . and brake servo vacuum hose from inlet manifold17.3  Disconnect coolant hoses (arrowed) . . .
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