| Fuel injection system components | removal and refitting. |
| Throttle body | |
| Note: Refer to the warning note in Section 1 before proceeding. | |
| Remove the air cleaner assembly, as described in Section 2. |
| Slacken and remove the bolt and retaining clip securing the fuel pipes to the bulkhead (see illustration). Examine the injector housing feel pipe feed and return unions for signs of leakage, then wipe them clean. |
| Bearing in mind the information contained in Section 6 on depressurising the fuel system, using an open-ended spanner to hold each adapter, unscrew the pipe union nuts, and release the fuel feed and return pipes from the adapters (see illustration). Plug each pipe and adapter, to minimise the loss of fuel and prevent the entry of dirt into the system. |
| Release the wire retaining clips, and disconnect the wiring connectors from the injector housing, the throttle potentiometer and the stepper motor. |
| Slacken the accelerator cable locknuts, and free the outer cable from its mounting bracket. Release the inner cable from the throttle cam. |
| Release the retaining clip(s), and disconnect the breather and purge valve hoses from the front of the throttle body (see illustration). |
| On models with automatic transmission, disconnect the governor control rod from the throttle linkage. |
| Slacken and remove the four nuts securing the throttle body to the inlet manifold, then remove the throttle body from the car. Remove the insulating spacer, and examine it for signs of wear or damage, renewing it if necessary. |
| If Ieakage was detected from the feed and return pipes or their union nuts, check the sealing surfaces of the nuts and adapters, and renew the adapter or the pipe assembly as necessary. If leakage was detected from the adapters, unscrew each through one turn with a spanner, then through two turns by hand; if the adapter is still a tight fit in the housing, the threads are damaged, and the housing and adapters must be renewed as a set. If the threads are sound, fit new sealing washers to the adapters and refit them, tightening them to their specified torque wrench setting. |
| Refitting | |
| Refitting is the reverse sequence to removal, noting the following points: | |
| a) Ensure that the mating surfaces of the throttle body and inlet manifold are clean, then fit the insulating spacer. |
| b) Tighten the throttle body nuts and fuel pipe union nuts to their specified torque settings. Note that when tightening the injector housing fuel pipe union nuts, do not use an open-ended spanner to retain the adapters; this will ensure that the adapters are securely tightened in the injector housing. |
| c) On completion, reconnect and adjust the accellerator cable as described in Section 4. |
| Injector housing | |
| Note: Refer to the warning note in Section 1 before proceeding | |
| Removal | |
| Carry out the operations described in paragraphs 1 to 3. |
| Release the wire retaining clip, and disconnect the wiring connector from the injector housing (see illustration). |
| Remove the four screws securing the injector housing to the throttle body (see illustration), then lift off the injector housing and remove the gasket. |
| If leakage was detected from the fuel feed and/or return pipes, perform the checks described in paragraph 9. |
| Refitting | |
| Refitting is the reverse sequence to removal, noting the following points: | |
| a) Ensure that the injector and throttle body mating surfaces are clean, and fit a new gasket. |
| b) Apply thread-locking compound (Rover recommended Locktite 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, noting that when tightening the union nuts, do not use an open-ended spanner to retain the adapters; this will ensure that the adapters are securely tightened in the housing. |
| Fuel injector | |
| Note: As a Rover replacement part, the injector is available only as part of the injector housing. Note, however, that it is a Bosch manufactured component, and can be obtained separately through Bosch agents. | |
| Refer to the warning note in Section 1 before proceeding | |
| Removal | |
| Disconnect the battery negative lead. |
| Remove the air cleaner assembly as described in Section 2. |
| Slacken and remove the injector connector cap retaining screw, and lift off the connector cap (see illustration). As the screw is slackened, place a clean rag over the cap to catch any fuel spray which may be released. |
| The injector can then be lifted out of the housing. |
| Refitting | |
| Refitting is the reverse sequence to removal, ensuring that the connector cap makes good contact with the injector pins. |
| Fuel pressure regulator | |
| The fuel pressure regulator is available only as part of the injector housing assembly. |
| Refer to paragraphs 11 to 15 for details on removal and refitting. |
| Stepper motor | |
| Removal | |
| Remove the injector housing as described in paragraphs 11 to 14. | |
| Release the retaining clip, and disconnect the Stepper motor wiring connecter. |
| Remove the four Stepper motor retaining screws, and remove the stepper motor assembly tom the throttle body. Do not attempt to dismantle the assembly. |
| Refitting | |
| Refitting is the reverse sequence to removal, ensuring that the throttle body and motor mating surfaces are clean. On completion, adjust the accelerator cable as described in Section 4, to ensure that the stepper motor is correctly indexed. |
| Throttle potentiometer | |
| Removal | |
| Although not strictly necessary, access is greatly improved if the air cleaner assembly is first removed, as described in Section 2. |
| Disconnect the battery negative lead. |
| Release the wire retaining clip, and disconnect the potentiometer wiring connector. |
| Remove the two screws, and remove the potentiometer from the throttle body, noting how its tongue engages with the throttle disc spindle lever. Withdraw the spacer if required. |
| Refitting | |
| Refitting is the reverse sequence to removal, noting the following points: | |
| 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 ECU | |
| Removal | |
| Disconnect the battery negative lead, and undo the two bolts securing the ECU mounting bracket to the right-hand wing valance (see illustration). |
| Withdraw the ECU from the engine compartment, disconnecting its wiring connectors and the manifold absolute pressure sensor vacuum hose as they become accessible (see illustration). |
| If necessary, undo the three screws and seperate the ECU from its mounting bracket. |
| Refitting | |
| Refitting is the reverse sequence to removal, ensuring that the wiring connectors and vacuum hose are securely reconnected. 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 (MAP) sensor | |
| This is part of the ECU, and is removed and refitted as descridbed in the previous subsection. |
| The sensor's vacuum hose runs from the inlet manifold to the ECU via a fuel (vapour) trap mounted on the engine compartment bulkhead. |
| To remove the fuel trap, first remove the air cleaner assembly as described in Section 2. Release the fuel trap from its retaining clip, then disconnect the two vacuum hoses, noting their correct fitted positions, and remove it from the engine compartment (see illustration). |
| On refitting, ensure that the vacuum hoses are reconnected to their original unions; the hoses are colour-coded to ensure correct reconnection. |
| Inlet air temperature sensor | |
| Removal | |
| Disconnect the battery negative lead. |
| Remove the air cleaner assembly as described in Section 2. |
| Unscrew the sensor, and remove it from the base of the air cleaner housing (see illustration). |
| Refitting | |
| Refitting is the reverse sequence to removal. Tighten the sensor to the specified tongue wrench setting. |
| Coolant temperature sensor | removal and refitting |
| Removal | |
| The coolant temperature sensor is fitted to the underside of the inlet manifold, and access to the sensor is strictly limited. |
| Therefore, to remove the sender, it will first be necessary to remove the inlet manifold as described in Section 15. The sensor can be unscrewed and removed from the manifold. |
| Refitting | |
| Wipe clean the threads of the switch and inlet manifold. If a sealing washer is fitted, apply a smear of sealant to the switch threads. |
| Refit the switch to the manifold, and tighten it securely. Refit the manifold as described in Section 15. |
| Accelerator pedal switch | |
| Removal | |
| Working from inside the car, release the heater duct from underneath the driver's side of the facia panel, and position it clear of the accelerator pedal. |
| Using a suitable pair of pliers, unhook the accelerator pedal return spring from the pedal. |
| Release the switch wiring connector from its retaining clip, and disconnect it (see illustration). |
| Slacken and remove the accelerator pedal switch mounting bracket retaining bolt, and remove the switch and bracket assembly from the car (see illustration). |
| Prise off the C-clip, and remove the switch from the mounting bracket, noting the wave washer which is fitted between the switch and bracket. |
| Refitting | |
| Refitting is the reverse sequence to removal. |
| Fuel cut-off inertia switch | |
| The fuel cut-off inertia switch is mounted onto the left-hand side of the engine compartment bulkhead (see illustration). If the switch has tripped, it can be reset by pressing in the button situanded at the top of the switch. |
| Removal | |
| Slacken and remove the two screws securing the cut-off switch to the bulkhead, then disconnect the wiring connector and remove the switch. |
| Refitting | |
| Reconnect the wiring connector, then refit the switch to the bulkhead and tighten its retaining screws securely. Reset the switch by depressing the button on the top of the switch. |
| Relay module | |
| The relay module contains the four main relays which control the engine management system; the sender relay, the fuel pump relay, the main relay and the manifold PTC heater relay. If a fault develops in any one of the system relays, the complete relay module must be renewed; it is not possible to renew the separate relays individually. |
| Removal | |
| Slide the relay off the mounting bracket in the right-hand rear corner of the engine compartment, then disconnect its wring connectors and remove it from the car (see illustration). |
| Reffitting | |
| Refitting is the reverse sequence to removal. |