Land Rover Rover 214 Repair 1689 04c Rover Manual

							1689 Rover 214 & 414 Updated Version 09/97
4C
Chapter 4 Part C
Fuel and exhaust systems - 
multi-point fuel injection engines
Air cleaner assembly - removal and refitting  . . . . . . . . . . . . . . . . . . . 3
Air cleaner filter element - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accelerator cable - removal, refitting and adjustment  . . . . . . . . . . . 10
Accelerator pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 11
Exhaust manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 17
Exhaust system - inspection, removal and refitting  . . . . . . . . . . . . . 18
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . . 8
Fuel injection system components - removal and refitting  . . . . . . . . 14
Fuel injection system components - testing  . . . . . . . . . . . . . . . . . . . 13Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel system - inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel system - pressure check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold pre-heater - operation, removal and refitting  . . . . . . . 15
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 16
Throttle housing - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 12
4C•1
Contents
Specifications
System
Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rover/Motorola Modular Engine Management System, using ECU-
controlled multi-point injection (MEMS-MPi) and speed/density
method of airflow measurement 
MEMS-MPi system data
Fuel pump type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric, immersed in fuel tank
Fuel pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 ± 0.2 bar constant
MEMS - ECU assembly:
Alloy inlet manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MNE 101470
Plastic inlet manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MKC 101730
Injectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MJY 10015
Throttle potentiometer voltage:
Throttle closed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 1 volt
Throttle open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 5 volt
Idle speed - nominal value given for reference purposes only  . . . . . . . . 850 ± 50 rpm
CO level at idle speed — engine at normal operating temperature  . . . . 0.5 %
Recommended fuel
Minimum octane rating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON unleaded (ie: unleaded Premium) only
Torque wrench settingsNm lbf ft
Fuel system
ECU mounting bracket nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Vent valve-to-fuel tank nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Vent pipe-to-fuel tank nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Fuel pump-to-fuel tank nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Fuel filter pressure release union  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28
Fuel feed hose union-to-body bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7
Fuel feed hose bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Fuel rail bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Fuel rail support bracket bolts - alloy manifold  . . . . . . . . . . . . . . . . . . . 10 7
Intake air temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Coolant temperature sensor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Crankshaft sensor bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4
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 (continued)
Throttle housing-to-alloy manifold nuts  . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Throttle housing-to-plastic manifold bolts  . . . . . . . . . . . . . . . . . . . . . . . 4 3
Throttle potentiometer screws - plastic manifold  . . . . . . . . . . . . . . . . . . 1.5 1.1
Stepper motor screws - plastic manifold  . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.1
Pressure regulator-to-fuel rail bolts - alloy manifold  . . . . . . . . . . . . . . . 10 8
Pressure release bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Inlet manifold mounting nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Exhaust system
Oxygen (lambda) sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 40
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
4C•2 Fuel and exhaust systems - multi-point fuel injection engines
1.0  Fuel and ignition system components - MEMS-MPi
2 Fuel cut-out inertia switch
3 Fuel pump
4 Throttle potentiometer
5 Fuel pressure regulator
6 Injectors
7 Stepper motor
8 Intake air temperature
sensor9 Coolant temperature
sensor
10 Distributor
11 Crankshaft sensor
12 Diagnostic connector
13 Engine management 
ECU
14 Main relay15 Fuel pump relay
16 Lambda sensor relay
17 Starter relay
18 Ignition HT coil
19 Purge valve
20 Lambda sensor
21 Charcoal canister
22 Fuel temperature sensor
1689 Rover 214 & 414 Updated Version 09/97
1 General information and
precautions
General information
The fuel system comprises a fuel tank
which is mounted under the rear of the vehicle
with an electric fuel pump immersed in it, a
fuel filter, fuel feed and return lines which
service four fuel injectors interlinked by a rail,
as well as the Electronic Control Unit (ECU)
and the various sensors, electrical
components and related wiring which make
up the system as a whole (see illustration).
Inlet manifolds of either alloy or plastic
construction are fitted.
The air cleaner assembly contains a
disposable paper filter element and is
mounted on the side of the battery tray.
To reduce emissions and to improve
driveability when the engine is cold, the inlet
manifold is heated by the coolant. Mixture
enrichment for cold starting is a pre-
programmed function of the system.
The ECU fully controls both the ignition
system and the fuel injection system,
integrating the two in a complete engine
management system (MEMS-MPi). System
operation is similar to that described for the
single-point fuel injection system (MEMS-SPi)
in Part B of this Chapter, any differences
being made clear in the following Sections.
Refer to Chapter 5 for information on the
ignition side of the system and to Chapter 12
for details of the system relays.
The exhaust system consists of four main
components which are the front downpipe,
the catalytic converter, the intermediate pipe
and middle silencer box, and the tailpipe and
main silencer box. The system is suspended
throughout its entire length by rubber
mountings.
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 coverters
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
1For improved access, remove the battery.
2Release the two securing clips and detach
the connecting hose from between the throttle
housing and air cleaner (see illustration).
Note that on engines fitted with a plastic inlet
manifold, the hose is secured to the throttle
housing with a spring clip.
3Remove the two battery tray-to-air cleaner
securing bolts (see illustration).
4Disconnect the HT coil-to-distributor cap
lead at the cap and from its retaining clip on
the air cleaner (see illustration).
5Pull the air cleaner assembly free of its
mounting bracket, release it from its inlet
hose, then remove it from the vehicle.
Refitting
6Refitting is the reverse of the removal
procedure. Ensure that all rubber mounting
grommets and hoses are free of splits or
perishing and that all hose clips are securely
tightened.
4 Fuel system- inspection
Refer to Chapter 1.
5 Fuel system-
depressurisation
2
Note:The following procedure will merely
relieve 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 is defined as the tank-
mounted fuel pump, the fuel filter, the fuel
injectors 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.
2The fuel system is depressurised by
loosening the fuel filter pipe union.
3Position wads of rag around the union to
catch spilled fuel. Carefully loosen the union
whilst holding the fuel pipe with an open-
ended spanner to prevent any undue strain
being placed upon it (see illustration).
4Once all pressure has been released,
retighten the union to the specified torque
setting whilst using a spanner to counter-hold
the pipe.
6 Fuel system- pressure check
1Fuel system testing will involve the use of
specialist Rover tools. Consult your Rover
dealer as to the availability of these tools and
refer to Section 7 in Part B of this Chapter and
to the figures given in the Specifications
Section before proceeding.
7 Fuel pump- 
removal and refitting
Refer to Section 8 in Part B of this Chapter.
8 Fuel gauge sender unit-
removal and refitting
Refer to Section 9 in Part A of this Chapter.
9 Fuel tank- 
removal and refitting
1Refer to Section 10 in Part A of this Chapter
but depressurise the fuel system before
disconnecting any of the fuel lines.
10 Accelerator cable- removal,
refitting and adjustment
2
Note:Before proceeding with any adjustment
of the accelerator cable, ensure that it is
correctly routed. Do not attempt to adjust the
cable by means of the throttle stop screw.
Removal
1Detatch the cable adjuster nut from its
abutment bracket and disengage the cable
Fuel and exhaust systems - multi-point fuel injection engines  4C•3
3.4  Releasing HT coil-to-distributor cap
lead from air cleaner3.3  Removing battery tray-to-air cleaner
securing bolts (arrowed)3.2  Releasing throttle housing-to-air
cleaner securing clips
5.3  Loosening fuel filter pipe union
4C
1689 Rover 214 & 414 Updated Version 09/97 
						

							end nipple from the throttle cam (see
illustration).
2On vehicles with an alloy inlet manifold,
release the cable from its retaining clip on the
engine compartment bulkhead (see
illustration).
3On vehicles with a plastic inlet manifold,
release the cable from its retaining clip on the
manifold.
4It may be necessary to remove the
windscreen wiper motor to gain access to
where the cable passes through the bulkhead. 
5Release the cable outer from the bulkhead
by turning its retaining clip (see illustration).
6Remove the cable inner-to-throttle pedal
securing clip and detach the cable from the
pedal.
7Withdraw the cable from the vehicle.
Refitting
8Refitting is the reverse of the removal
procedure. Adjust the cable as follows:
Adjustment
Alloy inlet manifold only
9Ensure that the throttle potentiometer and
stepper motor are synchronised.
10Turn the ignition on and wait for 10
seconds before turning the ignition off toensure that the stepper motor is in the setting
position. 
Alloy and plastic inlet manifolds
11Detach the cable adjuster nut from its
abutment bracket and reposition the cable
outer in the bracket.
12Turn the cable adjuster nut until it just
makes contact with the top of the abutment
bracket.
Alloy inlet manifold only
13Hold the cam in the “throttle closed”
position and ensure that the screw is in contact
with the stepper motor pin. Turn the cable
adjuster nut until all slack is removed from the
cable inner. Any linkage gap must be removed
without opening the throttle (see illustration).
Plastic inlet manifold only
14Hold the throttle cam in contact with the
throttle stop screw and turn the cable adjuster
nut until all slack is removed from the cable
inner. This must be achieved without opening
the throttle.
Alloy and plastic inlet manifolds
15Check that there is no free play in the
cable outer and refit the cable adjuster nut
into its abutment bracket.
16Operate the throttle pedal, checking that
the throttle opens to its stop.
11 Accelerator pedal- 
removal and refitting
Refer to Section 10 in Part A of this Chap-
ter.
12 Throttle housing- 
removal and refitting
2
Alloy inlet manifold
1Disconnect the battery earth lead.
2Release the two securing clips and 
detach the connecting hose from between the
throttle housing and air cleaner (see
illustration).
3Disconnect the stepper motor and throttle
potentiometer multiplugs.
4Disconnect the breather hose from the
throttle housing.
5Pull the accelerator cable adjuster nut from
its abutment bracket and release the cable
inner from the throttle cam.
6Remove the four nuts securing the throttle
housing to its mounting and remove the
housing from the vehicle.
7Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Examine the throttle housing mounting 
for splits or damage and renew if
necessary.
c) Tighten the housing securing nuts to the
specified torque wrench settings.
d) Check all hose connections are secure.
e) Check accelerator cable adjustment.
Plastic inlet manifold
8Disconnect the battery earth lead.
9Release the two securing clips and 
4C•4 Fuel and exhaust systems - multi-point fuel injection engines
12.2  Release hose securing clips (A),
disconnect stepper motor multiplug (B),
throttle potentiometer multiplug (C) and
breather hose (D)10.13  Turn accelerator cable adjuster 
nut (A) until all slack is removed from cable
inner. Any linkage gap (B) must be
removed without opening throttle
10.5  Release accelerator cable from
bulkhead by turning retaining clip
(arrowed)10.2  Releasing accelerator cable from
retaining clip on engine compartment
bulkhead10.1  Remove accelerator cable adjuster
nut from abutment bracket and disengage
cable end nipple from throttle cam
(arrowed)
1689 Rover 214 & 414 Updated Version 09/97 
						

							detach the connecting hose from between the
throttle housing and air cleaner (see
illustration).
10Loosen the stepper motor hose-to-throttle
housing retaining clip and detach the hose
from the housing.
11Disconnect the multiplug from the throttle
potentiometer.
12Disconnect the breather hose from the
throttle housing after loosening its retaining
clip. 
13Pull the accelerator cable adjuster nut
from its abutment bracket and release the
cable inner from the throttle cam.
14Remove the four bolts securing the
throttle housing to the inlet manifold, detach
the throttle housing from the manifold and
discard the sealing ring.
15Refitting is the reverse of the removal
procedure, noting the following.
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Fit a new throttle housing sealing ring,
lubricating it with silicone grease.c) Tighten the housing securing bolts to the
specified torque wrench settings.
d) Check all hose connections are secure.
e) Check accelerator cable adjustment.
13 Fuel injection system
components- testing
Refer to Section 14 in Part B of this Chap-
ter.
14 Fuel injection system
components- 
removal and refitting
3
Fuel rail/injectors
Alloy inlet manifold
1Disconnect the battery earth lead.
2Depressurise the fuel system.
3Detach the inlet manifold chamber and
discard the gasket.4Remove the two bolts securing the fuel
feed hose to the fuel rail and release the hose
from the rail, discarding the O-ring (see
illustration).
5Disconnect the four injector multiplugs.
6Release the retaining clip and disconnect
the hose from the fuel pressure regulator.
7Remove the two bolts securing the fuel rail
to the inlet manifold.
8Pull each injector from its location in the
inlet manifold and remove the fuel rail,
complete with injectors and pressure
regulator, from the vehicle, placing it on a
clean surface. 
9Remove and discard the O-ring fitted to the
base of each injector, then cover the exposed
end of each injector to prevent the ingress of
dirt or moisture (see illustration).  
10To remove the injectors from the fuel rail,
first remove the spring clip which secures
each injector to the rail (see illustration). 
Pull each injector from the rail and discard the
O-ring fitted to its upper end. Again, cover the
exposed end of each injector to prevent the
ingress of dirt or moisture.  
11Refitting of the injectors and rail is the
reverse of the removal procedure, noting the
following:
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Fit new O-rings, lubricating them with
clean fuel. 
c) Where applicable, tighten all securing
bolts to the specified torque wrench
settings.
Plastic inlet manifold
12Disconnect the battery earth lead.
13Depressurise the fuel system.
14Loosen the throttle housing breather
Fuel and exhaust systems - multi-point fuel injection engines  4C•5
14.4  Fuel rail/injector assembly - alloy inlet manifold
A Fuel feed hose connection
B O-ring
C Injector multiplug (1 of 4)
D Fuel pressure regulatorE Fuel rail securing bolts
F Fuel injector (1 of 4)
G Fuel rail
14.10  Remove spring clip (A), pull injec-
tor (B) from rail and discard O-ring (C)14.9  Discard O-ring (arrowed) fitted to
injector base
12.9  Throttle housing assembly - plastic inlet manifold
A Hose securing clips
B Stepper motor hose
C Throttle potentiometer
multiplug
D Throttle housing breather
hoseE Throttle cable adjuster
F Throttle cam
G Throttle housing securing
bolts (two shown)
4C
1689 Rover 214 & 414 Updated Version 09/97 
						

							hose-to-camshaft cover retaining clip and
detach the hose (see illustration).
15Disconnect the multiplug from the stepper
motor.
16Disconnect the inlet manifold breather
hose from the camshaft cover.
17Disconnect the vacuum pipe from the fuel
pressure regulator.
18Loosen the retaining clip and disconnect
the fuel return hose from the fuel rail.
19Remove the two bolts which secure the
fuel feed pipe to the fuel rail and release the
pipe from the rail, discarding the O-ring (see
illustration 14.4).
20Disconnect each injector multiplug and
securing clip.
21Remove the two bolts securing the fuel
rail to the inlet manifold and detach the rail
from the manifold, together with the fuel
pressure regulator.
22Note that the rail and regulator are
serviced as an assembly and should not be
separated. If unions are to be left
disconnected for any length of time, then plug
them with clean cloth to prevent the ingress of
dirt or moisture into the system.
23To remove the injectors, pull each one
from its location in the inlet manifold and
discard both of its O-rings. If leaving the
injectors for any length of time, cover their
exposed ends to prevent the ingress of dirt or
moisture.  
24Refitting of the injectors and rail is the
reverse of the removal procedure, noting the
following:
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Fit new O-rings, lubricating them with
silicone grease. 
c) Where applicable, tighten all securing
bolts to the specified torque wrench
settings.
Fuel pressure regulator
Alloy inlet manifold
25The fuel pressure regulator is secured to
the end of the fuel rail by two bolts (see
illustration). 
26With fuel system pressure released and
the fuel hose disconnected from the regulator
(see fuel rail removal above), remove the
securing bolts and detach the regulator from
the rail.
27Remove the spacer and O-ring,
discarding the O-ring.
28Refitting the regulator is the reverse of the
removal procedure. Thoroughly clean the
mating surfaces and fit a new O-ring,
lubricating it with clean fuel. 
Plastic inlet manifold
29The fuel pressure regulator is available
only as part of the fuel rail and should not be
separated from the same.
Stepper motor
Alloy inlet manifold
30The stepper motor fitted to this type of
manifold is an integral part of the throttle
housing and as a consequence, cannot be
removed.
Plastic inlet manifold
31Disconnect the multiplug from the stepper
motor (see illustration).
32Remove the two Torx screws whichsecure the motor to the inlet manifold and
remove the motor, discarding its O-ring.
33Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean the mating surfaces.
b) Fit a new O-ring to the motor, lubricating
it with silicone grease.
c) Tighten the motor securing bolts to the
specified torque wrench setting.
Throttle potentiometer
Alloy inlet manifold
34Disconnect the battery earth lead.
35Disconnect the multiplug from the
potentiometer (see illustration).
36Remove the two securing screws and
detach the potentiometer from the throttle
housing.
37Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean the mating surfaces.
b) Ensure correct engagement of the
potentiometer before fitting the securing
screws.
Plastic inlet manifold
38Disconnect the potentiometer multiplug
(see illustration).
39Remove and discard the two securing
screws and wavewashers and remove the
clamping plate.
40Pull the potentiometer off the throttle
spindle being carefull not to apply leverage or
twist the potentiometer.
4C•6 Fuel and exhaust systems - multi-point fuel injection engines
14.38  Potentiometer multiplug (arrowed) -
plastic inlet manifold14.35  Disconnecting potentiometer
multiplug - alloy inlet manifold
14.31  Disconnect stepper motor 
multiplug (A) and remove Torx screws 
(B - one hidden)14.25  Fuel pressure regulator location -
alloy inlet manifold
1689 Rover 214 & 414 Updated Version 09/97
14.14  Fuel rail/injector components -
plastic inlet manifold
A Throttle housing breather hose
B Inlet manifold breather hose
C Fuel pressure regulator
D Fuel return hose
E Fuel rail securing bolt (1 of 2)
F Fuel injector multiplug (1 of 4)
G Fuel injecdtor securing clip (1 of 4) 
						

							41Refitting is the reverse of the removal
procedure, noting the following:
a) Carefully clean the mating surfaces of the
throttle housing and potentiometer.
b) Refit the potentiometer so that the flat on
the spindle is aligned with the mating
portion of the potentiometer.
c) When pressing the potentiometer onto
the spindle, apply finger pressure only to
the shaded area shown (see illustration).
d) Rotate the potentiometer anti-clockwise
only to align the fixing holes.
e) Tighten the potentiometer screws to their
specified torque wrench setting.
f) Operate the throttle cam 2 or 3 times 
and ensure that full travel exists
between the throttle open and closed
positions.
Engine management
(ignition/fuel injection) ECU
42Remove the battery.
43Undo the three nuts securing the ECU to
its mounting bracket (see illustration).
44Unplug the two multiplug connectors from
the ECU.
45Release the securing clip and pull the
vacuum hose from the ECU.
46Remove the ECU from the vehicle.
47Refitting the ECU is the reverse of the
removal procedure. If a new or different ECU
has been fitted, it may take a short while for
full idle control to be restored.
Intake air temperature sensor
48Disconnect the battery earth lead.
49Disconnect the sensor multiplug and
unscrew the sensor from the inlet manifold
(see illustration).
50Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean the sensor threads and
mating surfaces.
b) Tighten the sensor to the specified torque
wrench setting.
Coolant temperature sensor
51Disconnect the battery earth lead.
52Either drain the cooling system or be
prepared for some loss of coolant as the
sensor is unscrewed.
53Disconnect the sensor multiplug (see
illustration).
54Unscrew the sensor and withdraw it, then
plug the opening to prevent any entry of dirt. If
the cooling system has not been drained,
work quickly to minimise coolant loss.
55Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean the sensor threads and
mating surfaces.
b) If a sealing washer is fitted, renew it. If no
sealing washer is fitted, apply a smear of
sealant to the sensor threads.c) Tighten the sensor to the specified torque
wrench setting.
d) On completion, replenish the cooling
system.
Accelerator pedal switch
56Refer to Section 11 in Part A of this
Chapter.
Fuel cut-off inertia switch
57Refer to Section 15 in Part B of this
Chapter.
Relays
58Refer to Chapter 12 for further
information.
15 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.
16 Inlet manifold- 
removal and refitting
3
Alloy inlet manifold
Removal
1Disconnect the battery earth lead.
2Depressurise the fuel system.
3Disconnect the hose from the fuel filter,
covering the open connections to prevent any
ingress of dirt.
4Refer to Chapter 1 and drain the cooling
system.
5Release the securing clip and detach the
throttle housing-to-air cleaner hose from the
throttle housing.
6Disconnect the stepper motor and throttle
potentiometer multiplugs (see illustration).
7Disconnect the breather hose from the
throttle housing.
Fuel and exhaust systems - multi-point fuel injection engines  4C•7
14.49  Intake air temperature sensor
multiplug (arrowed)
14.43  ECU connection points
A Mounting nuts
B Multiplug connectors
C Vacuum hose
14.41 When pressing potentiometer onto
spindle, apply finger pressure only to
shaded area
16.6  Disconnecting stepper motor
multiplug14.53  Coolant temperature sensor
multiplug (arrowed)
4C
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							8Release the retaining clip and disconnect
the breather pipe from the manifold chamber
(see illustration).
9Release the retaining clips and disconnect
the three breather hoses from the manifold
chamber (see illustration, also illus-
tration 16.8).
10Unscrew the brake servo line banjo bolt
from the manifold chamber, discarding both
sealing washers (see illustration).
11Remove the five bolts securing the
manifold chamber to the inlet manifold. 
12Remove the support stay to manifold
chamber securing bolt.
13Detach the manifold chamber from the
inlet manifold and discard its gasket.
14Remove the engine oil dipstick, covering
the open pipe to prevent any ingress of dirt.
15Disconnect the four fuel injector
multiplugs and the intake air temperature
sensor multiplug.
16Release the coolant hose from the inlet
manifold (see illustration).
17Remove the two nuts and three bolts
securing the upper face of the inlet manifold
to the cylinder head, loosening each one a
little at a time.
18Remove the two bolts securing the engine
wiring harness brackets to the inlet manifold.
19Release the two clips which secure the
fuel return hose.20Remove the bolt securing the support
stay to the inlet manifold.
21Remove the four bolts securing the lower
face of the inlet manifold to the cylinder head,
loosening each one a little at a time.
22Remove the inlet manifold, discarding the
gasket.
Refitting
23Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Always fit a new manifold gasket.
c) Working in the sequence shown (see
illustration), tighten the manifold
retaining nuts and bolts evenly to the
specified torque wrench setting.
d) Tighten all disturbed fasteners to their
specified torque wrench settings (where
given).
e) Renew all sealing washers and O-rings. 
f) Remove all masking materials.
g) Ensure all hose connections are securely
remade.
h) Ensure the brake servo line banjo union
alignment tang is located in the manifold
chamber slot.
i) Refill the cooling system and check the
coolant level, then wash off any spilt
coolant.
Plastic inlet manifold
Removal
24Disconnect the battery earth lead.25Depressurise the fuel system.
26Refer to Chapter 1 and drain the cooling
system.
27Release the securing clip and detach the
throttle housing-to-air cleaner hose from the
air cleaner.
28Release the retaining clip and detach the
purge hose from the inlet manifold (see
illustration).
29Disconnect the breather hose from the
throttle housing after loosening its retaining
clip. 
30Disconnect the multiplug from the throttle
potentiometer.
31Loosen the stepper motor hose-to-
abutment retaining clip and detach the hose,
moving it to one side.
32Release the accelerator cable from its
retaining clip on the right-hand side of the
manifold.
33Remove the four bolts securing the
throttle housing to the inlet manifold.
34Detach the throttle housing from the
manifold and discard its sealing ring.
35Disconnect the multiplug from the stepper
motor.
36Release the breather hose from the inlet
manifold and depress the plastic collar of the
brake servo hose quick-fit connector to
4C•8 Fuel and exhaust systems - multi-point fuel injection engines
16.28  Throttle housing connections -
plastic inlet manifold
A Purge hose
B Breather hose
C Throttle potentiometer
D Stepper motor hose
16.23  Alloy inlet manifold tightening
sequence
16.10  Brake servo line banjo union
A Sealing washers
B Union alignment tang in manifold
chamber slot
16.16  Releasing coolant hose from inlet
manifold
16.9  Disconnect breather hoses (arrowed)
from manifold chamber16.8  Disconnect breather pipe (A) from
manifold chamber
B  Manifold chamber breather hose (1 of 3)
1689 Rover 214 & 414 Updated Version 09/97 
						

							release it from the manifold (see
illustrations).
37Disconnect the ECU vacuum pipe from
the manifold.
38Loosen the retaining clip and disconnect
the fuel return hose from the fuel rail, covering
the open connections to prevent any ingress
of dirt (see illustration).
39Disconnect the coolant system expansion
tank hose from the inlet manifold.
40Release the fuel return hose from its
retaining clips.
41Disconnect the injector harness and air
temperature sensor multiplugs.
42Remove the two bolts which secure the
fuel feed pipe to the fuel rail and release the
pipe from the rail. Discard the O-ring and
cover the open connections to prevent any
ingress of dirt.
43Working from the centre of the manifold
outwards, progressively loosen the manifold
securing nuts and bolts. Remove the
manifold, discarding the gasket.
Refitting
44Refitting is the reverse of the removal
procedure, noting the following:
a) Thoroughly clean all component parts,
paying particular attention to the mating
surfaces.
b) Ensure that a metal insert is located in
each manifold stud or bolt hole.
c) Always fit a new manifold gasket (see
illustration).
d) Working in the sequence shown (see
illustration), tighten the manifoldretaining nuts and bolts evenly to the
specified torque wrench setting.
e) Tighten all disturbed fasteners to their
specified torque wrench settings (where
given).
f) Fit new O-rings, lubricating them with
silicone grease. 
g) Remove all masking materials.
h) Ensure all hose connections are securely
remade.
i) Refill the cooling system and check the
coolant level, then wash off any spilt
coolant.
17 Exhaust manifold- 
removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Remove the air cleaner assembly.
3Remove the alternator.
4Referring to Part D of this Chapter, release
the lambda sensor multiplug from the gearbox
bracket and disconnect the plug from the
sensor.
5Firmly apply the handbrake then jack up the
front of the vehicle and support it on axle
stands.
6Unscrew the nuts securing the exhaust
front pipe to the manifold, then disconnect the
pipe and collect the gasket.7Undo the five nuts securing the exhaust
manifold to the cylinder head, then carefully
manoeuvre the manifold out of the engine
compartment. Remove the manifold gasket
and discard it.
8Examine all the exhaust manifold studs for
signs of damage and corrosion. Remove all
traces of corrosion and repair or renew any
damaged studs.
Refitting
9Refitting is the reverse of the removal
procedure, noting the following:
a) Ensure that the manifold and cylinder
head sealing faces are clean and flat, then
fit a new manifold gasket.
b) Working in the sequence shown (see
illustration), tighten the manifold
retaining nuts evenly to the specified
torque wrench setting.
c) Tighten all other disturbed nuts and bolts
to their specified torque wrench settings
(where given).
18 Exhaust system-
inspection,removal and
refitting
1Refer to Section 18 in Part A of this
Chapter. Note that on models fitted with a
closed-loop catalytic converter, the lambda
sensor must be removed or its wiring
disconnected whenever the exhaust system
front pipe is disconnected from the manifold.
Fuel and exhaust systems - multi-point fuel injection engines  4C•9
16.38  Disconnect fuel return hose (A) and
expansion tank hose (B)16.36b . . . and depress plastic collar
(arrowed) of brake servo hose quick-fit
connector to release from manifold
A  ECU vacuum pipe
17.9  Exhaust manifold tightening
sequence16.44b  Plastic inlet manifold tightening
sequence16.44a  Fit a new inlet manifold gasket
(arrowed)
4C
1689 Rover 214 & 414 Updated Version 09/97 16.36a  Release breather hose 
(arrowed) . . .